Force prediction model for five-axis flat end milling of free-form surface based on analytical CWE

2018 ◽  
Vol 99 (1-4) ◽  
pp. 1023-1036 ◽  
Author(s):  
M. L. Guo ◽  
Z. C. Wei ◽  
M. J. Wang ◽  
S. Q. Li ◽  
S. X. Liu
Keyword(s):  
Prediction Model ◽  
End Milling ◽  
Free Form ◽  
Force Prediction ◽  
Flat End Milling ◽  
Free Form Surface ◽  
Five Axis

scholarly journals Cutting Force Modeling and Experimental Study for Ball-End Milling of Free-Form Surfaces

2021 ◽  
Vol 2021 ◽  
pp. 1-18
Author(s):  
Zhaozhao Lei ◽  
Xiaojun Lin ◽  
Gang Wu ◽  
Luzhou Sun
Keyword(s):  
Prediction Model ◽  
Cutting Force ◽  
Chip Thickness ◽  
Free Form ◽  
Force Model ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Undeformed Chip Thickness ◽  
Free Form Surface ◽  
Free Form Surfaces

In order to improve the machining quality and efficiency and optimize NC machining programming, based on the existing cutting force models for ball-end, a cutting force prediction model of free-form surface for ball-end was established. By analyzing the force of the system during the cutting process, we obtained the expression equation of the instantaneous undeformed chip thickness during the milling process and then determined the rule of the influence of the lead angle and the tilt angle on the instantaneous undeformed chip thickness. It was judged whether the cutter edge microelement is involved in cutting, and the algorithm flow chart is given. After that, the cutting force prediction model of free-form surface for ball-end and pseudocodes for cutting force prediction were given. MATLAB was used to simulate the prediction force model. Finally, through the comparative analysis experiment of the measured cutting force and the simulated cutting force, the experimental results are basically consistent with the theoretical prediction results, which proves that the model established in this paper can accurately predict the change of the cutting force of the ball-end cutter in the process of milling free-form surface, and the error of the cutting force prediction model established in this paper is reduced by 15% compared with the traditional cutting force prediction model.

Virtual Five-Axis Milling of Free-Form Surface-Part I: Process Modeling

2010 ◽  
Vol 29-32 ◽  
pp. 424-429
Author(s):  
Li Qiang Zhang ◽  
Ye Cui Yan
Keyword(s):  
Cutting Forces ◽  
Cutting Parameters ◽  
Physical Models ◽  
Free Form ◽  
Cutting Force Prediction ◽  
Surface Machining ◽  
Force Prediction ◽  
Part Quality ◽  
Free Form Surface ◽  
Five Axis

In free-form surface machining, it is essential to optimize the feedrate in order to improve the machining efficiency. This work is the first of a two part paper on cutting force prediction and feedrate optimization for five-axis milling. Conservative cutting parameters have been mostly used since there was a lack of physical models and optimization tools. Part and tool deflections under high cutting forces may result in poor part quality. The extracted cutter workpiece engagements are used as input to a force prediction model. The predicted cutting forces are shown to be in reasonable agreement with those collection during a roughing operation on a dual blades part.

Dynamics and Stability Prediction of Five-Axis Flat-End Milling

2017 ◽  
Vol 139 (6) ◽  
Author(s):  
YaoAn Lu ◽  
Ye Ding ◽  
LiMin Zhu
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Stability Prediction ◽  
Tool Orientation ◽  
Cutting Force Prediction ◽  
Vector Method ◽  
Force Prediction ◽  
Flat End Milling ◽  
The Stability ◽  
Five Axis

The tool orientation of a flat-end cutter, determined by the lead and tilt angles of the cutter, can be optimized to increase the machining strip width. However, few studies focus on the effects of tool orientation on the five-axis milling process stability with flat-end cutters. Stability prediction starts with cutting force prediction, and the cutting force prediction is affected by the cutter-workpiece engagement (CWE). The engagement geometries occur between the flat-end cutter and the in-process workpiece (IPW) are complicated in five-axis milling, making the stability analysis for five-axis flat-end milling difficult. The robust discrete vector method (DVM) is adopted to identify the CWE for flat-end millings, and it can be extended to apply to general cutter millings. The milling system is then modeled as a two-degrees-of-freedom spring-mass-damper system with the predicted cutting forces. Thereafter, a general formulation for the dynamic milling system is developed considering the regenerative effect and the mode coupling effect simultaneously. Finally, an enhanced numerical integration method (NIM) is developed to predict the stability limits in flat-end milling with different tool orientations. Effectiveness of the strategy is validated by conducting experiments on five-axis flat-end milling.

Tool Path Generation for Five-Axis Controlled Machining of Free-Form Surface Using Barrel Tool: Control of Contact Point on Cutting Edge

2020 ◽  
Author(s):  
Tomonobu Suzuki ◽  
Koichi Morishige
Keyword(s):  
Tool Path ◽  
Contact Point ◽  
Cutting Edge ◽  
Free Form ◽  
End Mill ◽  
Ball End Mill ◽  
Surface Machining ◽  
Free Form Surface ◽  
The Cost ◽  
Five Axis

Abstract This study aimed to improve the efficiency of free-form surface machining by using a five-axis controlled machine tool and a barrel tool. The barrel tool has cutting edges, with curvature smaller than the radius, increasing the pick feed width compared with a conventional ball end mill of the same tool radius. As a result, the machining efficiency can be improved; however, the cost of the barrel tool is high and difficult to reground. In this study, a method to obtain the cutting points that make the cusp height below the target value is proposed. Moreover, a method to improve the tool life by continuously and uniformly changing the contact point on the cutting edge is proposed. The usefulness of the developed method is confirmed through machining simulations.

Milling Force Prediction Model for Five-Axis Machining of Freeform Surface Considering Mesoscopic Size Effect

2021 ◽  
Vol 143 (9) ◽  
Author(s):  
Minglong Guo ◽  
Zhaocheng Wei ◽  
Minjie Wang ◽  
Jia Wang ◽  
Shengxian Liu
Keyword(s):  
Dislocation Density ◽  
Size Effect ◽  
Prediction Model ◽  
Cutting Force ◽  
Freeform Surface ◽  
End Mill ◽  
Ball End Mill ◽  
Milling Force ◽  
Force Prediction ◽  
Five Axis

Abstract The core parts with the characteristic of freeform surface are widely used in the major equipment of various fields. Cutting force is the most important physical quantity in the five-axis CNC machining process of core parts. Not only in micro-milling, but also in macro-milling, there is also an obvious size effect, especially in medium- and high-speed milling, which is frequently ignored. In this paper, the milling force prediction model for five-axis machining of a freeform surface with a ball-end mill considering the mesoscopic size effect is established. Based on the characteristics of cutting thickness in macro-milling, a new dislocation density correction form is proposed, and a new experiment is designed to identify the dislocation density correction coefficient. Therefore, the shear stress calculated in this paper not only reflects the cutting dynamic mechanical characteristics but also considers the mesoscopic size effect. A linear function is proposed to describe the relationship between friction coefficient and cutting speed, cutter rake angle, and cutting thickness. Considering cutter run-out, the micro-element cutting force in the shear zone and plough zone are analyzed. The cutting geometry contact between the freeform surface and the ball-end mill is analyzed analytically by the space limitation method. Finally, the total milling force is obtained by summing all the force vectors of cutting edge micro-elements within the in-cut cutting edge. In the five-axis machining experiment of freeform surface, the theoretically predicted results of milling forces are in good agreement with the measured results in trend and amplitude.

Tool Path Generation Method of Equal Approximation Error for Free-Form Surface in High Speed Machining

2010 ◽  
Vol 102-104 ◽  
pp. 544-549 ◽  
Author(s):  
Chun Jiang Zhou ◽  
Hong Chun Chen
Keyword(s):  
High Speed ◽  
Tool Path ◽  
Cutting Tool ◽  
End Milling ◽  
Approximation Error ◽  
Tool Path Generation ◽  
Free Form ◽  
Path Generation ◽  
High Speed Machining ◽  
Free Form Surface

The development of surface high-speed machining has put forward higher demands for uniform cutting load and smooth cutting tool path. Most current tool-path planning methods are based on constant scallop height, but they have the disadvantage of path point redundancy during the path discretization process. To overcome the problem, a tool path generation method of equal approximation error in each step for free-form surface is presented based on geodesic principle and curvature judgment. In this method, the NURBS curve is employed to realize smooth transition for adjacent two tool paths in high-speed machining. A certain angle of inclination of flat-end milling cutter during multi-axis machining improves the machining efficiency. Because of the advantage of this machining condition, the cutter location point generation algorithm during the machining condition is given by the method. The method is verified and simulated by C++. Experiment results proved that it can obtain uniform cutting load and continuous smooth cutting tool path during surface high-speed machining by the proposed method.

An approach to the evaluation of multivariate data during ball end milling free-form surface fragments

Measurement ◽  
2016 ◽  
Vol 84 ◽  
pp. 7-20 ◽  
Author(s):  
Jozef Beňo ◽  
Ildikó Maňková ◽  
Peter Ižol ◽  
Marek Vrabel’
Keyword(s):  
End Milling ◽  
Multivariate Data ◽  
Free Form ◽  
Ball End Milling ◽  
Free Form Surface
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