Modeling of surface topography based on cutting vibration in ball-end milling of thin-walled parts

2018 ◽  
Vol 101 (5-8) ◽  
pp. 1837-1854 ◽  
Author(s):  
Zhenhua Wang ◽  
Boxiang Wang ◽  
Juntang Yuan
Keyword(s):  
Surface Topography ◽  
End Milling ◽  
Ball End Milling ◽  
Cutting Vibration ◽  
Thin Walled

Experimental Investigation of the Effect of the Machine Kinematic Behavior on the Surface Topography and Roughness in High Speed Ball end Milling of the AISI4142 Steel

2021 ◽  
Author(s):  
Sai Lotfi ◽  
Belguith Rami ◽  
Baili Maher ◽  
Desseins Gilles ◽  
Bouzid Wassila
Keyword(s):  
Surface Topography ◽  
High Speed ◽  
End Milling ◽  
Experimental Investigations ◽  
Ball End Milling ◽  
Tool Paths ◽  
Stationary Zone ◽  
Machining Errors ◽  
Kinematic Behavior ◽  
Milling Tool

Abstract The analysis of the surface topography in ball end milling is an objective studied by many researchers, several methods were used and many combinations of cutting conditions and machining errors are considered. In the milling tool paths the trajectories presents a points of changing direction where the tool decelerates before and accelerates after respecting the velocity profiles of the machine. In this paper, we propose experimental investigations of the effect of the kinematic behavior of the machine tool on the surface quality. A poor topography and roughness are remarked on the deceleration and the acceleration zones compared to the stationary zone.

A New Algorithm for the Numerical Simulation of Machined Surface Topography in Multiaxis Ball-End Milling

2008 ◽  
Vol 130 (1) ◽  
Author(s):  
Wei-Hong Zhang ◽  
Gang Tan ◽  
Min Wan ◽  
Tong Gao ◽  
David Hicham Bassir
Keyword(s):  
Numerical Simulation ◽  
Surface Topography ◽  
End Milling ◽  
Computing Time ◽  
Cutting Edge ◽  
Machining Parameters ◽  
Step Method ◽  
Time Step ◽  
Machined Surface ◽  
Ball End Milling

In milling process, surface topography is a significant factor that affects directly the surface integrity and constitutes a supplement to the form error associated with the workpiece deformation. Based on the tool machining paths and the trajectory equation of the cutting edge relative to the workpiece, a new and general iterative algorithm is developed here for the numerical simulation of the machined surface topography in multiaxis ball-end milling. The influences of machining parameters such as the milling modes, cutter runout, cutter inclination direction, and inclination angle upon the topography and surface roughness values are studied in detail. Compared with existing methods, the basic advantages and novelties of the proposed method can be resumed below. First, it is unnecessary to discretize the cutting edge and tool feed motion and rotation motion. Second, influences of cutting modes and cutter inclinations are studied systematically and explicitly for the first time. The generality of the algorithm makes it possible to calculate the pointwise topography value on any sculptured surface of the workpiece. Besides, the proposed method is proved to be more efficient in saving computing time than the time step method that is commonly used. Finally, some examples are presented and simulation results are compared with experimental ones.

Geometrical simulation and analysis of ball-end milling surface topography

2019 ◽  
Vol 102 (5-8) ◽  
pp. 1885-1900 ◽  
Author(s):  
Li Shujuan ◽  
Yongheng Dong ◽  
Yan Li ◽  
Pengyang Li ◽  
Zhenchao Yang ◽  
...  
Keyword(s):  
Surface Topography ◽  
End Milling ◽  
Ball End Milling ◽  
Geometrical Simulation

Surface Topography and Roughness Simulations for 5-Axis Ball-End Milling

2009 ◽  
Vol 69-70 ◽  
pp. 471-475 ◽  
Author(s):  
Shi Guo Han ◽  
Jun Zhao ◽  
Xiao Feng Zhang
Keyword(s):  
Surface Topography ◽  
Surface Quality ◽  
High Speed ◽  
End Milling ◽  
Analytical Form ◽  
Influential Factors ◽  
Sculptured Surfaces ◽  
Machined Surface ◽  
Ball End Milling ◽  
Five Axis

In five-axis high speed milling of freeform surface with ball-end cutters, unwanted machining results are usually introduced by some error effects. Hence precise modeling and simulation of milled sculptured surfaces topography and roughness is the key to obtain optimal process parameters, satisfactory surface quality and high machining efficiency. In this paper, a predictive model for sculptured surface topography and roughness of ball-end milling is developed. Firstly, a mathematical model including both the relative motion of the cutter-workpiece couple and some influential factors on machined surface quality such as the tool runout, tool deflection and tool wear is proposed, and subsequently the analytical form of the tool swept envelope is derived by means of homogeneous coordinate transformation. Then the minimal z-values of the corresponding points lied in discrete cutting edges model and Z-map workpiece model are used to update the workpiece surface topography and to calculate 3D surface roughness. Finally, the simulation algorithm is realized with Matlab software. A series of machining tests on 3Cr2MoNi steel are conducted to validate the model, and the machined surface topography is found in good accordance with the simulation result.

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