Numerical simulation of chip ploughing volume in micro ball-end mill machining

2017 ◽  
Vol 18 (7) ◽  
pp. 915-922 ◽  
Author(s):  
Shan Luo ◽  
Abdolreza Bayesteh ◽  
Junghyuk Ko ◽  
Zuomin Dong ◽  
Martin B. Jun
Keyword(s):  
Numerical Simulation ◽  
End Mill ◽  
Ball End Mill ◽  
Mill Machining

A Novel CNC Grinding Method for Relief Surface Based on a CAM System

2011 ◽  
Vol 295-297 ◽  
pp. 2521-2525 ◽  
Author(s):  
Xiao Feng Yue ◽  
Fei Tang ◽  
Shu Zhe Li ◽  
Zhan Hua You ◽  
Xiao Hao Wang
Keyword(s):  
Coordinate System ◽  
Numerical Control ◽  
Grinding Wheel ◽  
End Mill ◽  
Ball End Mill ◽  
Relief Surface ◽  
Cnc Grinding ◽  
Relief Angle ◽  
Five Axis ◽  
Mill Machining

A novel algorithm for the ball-end mill relief using a five-axis computer numerical control (CNC) grinding machine and the simulation of the ball-end mill based on a CAM system is presented in this paper. In this study, In order to obtain an accurate normal relief angle, which is one of the key factors affecting tool cutting performance, a tool coordinate system based on the required relief angle and the cutting edge was established. Then, by the proposed tool coordinate system, an algorithm to determine the position between the grinding wheel and the tool is proposed, and then the relevant formulations are deduced. The coordinates of grinding point when the step of relief surface is grinded are calculated.Using the input data of a ball-end mill geometry, wheels geometry, wheel setting and machine setting, the NC code for machining will be generated. Then the code will be used as input to simulate the ball-end mill machining in 3 Dimension before real machining. The algorithm of ball-end mill relief can be authenticated by the 3D simulation system.

A Practical Algorithm for Ball-End Mill Using a Five-Axis CNC Grinding Machine

2012 ◽  
Vol 605-607 ◽  
pp. 1531-1536
Author(s):  
Xiao Jun Sun ◽  
Fei Tang ◽  
Xiao Hao Wang
Keyword(s):  
Mathematical Model ◽  
Cnc Machining ◽  
Grinding Wheel ◽  
Structural Parameter ◽  
End Mill ◽  
Ball End Mill ◽  
Local Coordinates ◽  
Five Axis ◽  
Mill Machining ◽  
The Mathematical Model

A novel ball-end mill manufacturing algorithm of 5-Axis CNC Machining grinder and the simulation test of the algorithm based on a CAD system are presented in this paper. In order to obtain an accurate algorithm of a ball end mill machining, a mathematical model is needed so that the shape of the mill can be parameterized. Therefore, the mathematical model can be adjusted based on that model. Each of the processing parts has its own position in the local coordinates system. Then, with the coordinates determined by the mathematical model, the partial coordinate and the relative movement between the grinding wheel and the barstock in the local coordinates system can be calculated. So that the 5-Axis manufacturing coordinate can be confirmed by the partial coordinate and the structural parameter. If we input these data and make the 3D-CAD simulation before the machinery manufacture, the algorithm can be tested effectively.

Modeling of Cutting Process with Cutter Axis Inclination

2011 ◽  
Vol 223 ◽  
pp. 66-74 ◽  
Author(s):  
Takashi Matsumura
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Cutting Temperature ◽  
Cutting Process ◽  
Mechanistic Models ◽  
End Mill ◽  
High Quality ◽  
Ball End Mill ◽  
Milling Operations ◽  
Edge Roughness

Multi-axis controlled machining has been increasing with the demand for high quality in mold manufacturing. The cutter axis inclination should be properly determined in the milling operations. The paper discusses the cutting process of ball end mill with the cutter axis inclination. Two mechanistic models are presented to show the effect of the cutter axis inclination on the tool wear and the surface finish. The actual cutting time during a rotation of the cutter reduces with increasing the cutter axis inclination. Then, the tool is cooled in the non-cutting time. The tool wear is suppressed with reducing the cutting temperature. The surface finish is also improved by increasing cutting velocities with the cutter axis inclination. When the cutter is inclined in the feed direction, the effect of the edge roughness on the surface finish is eliminated. The discussion based on the simulation is verified in the cutting tests for brittle materials.

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.

The Milling Cutter Design and Simulation for Complex Cavity Machining

2014 ◽  
Vol 800-801 ◽  
pp. 465-469
Author(s):  
An Shan Zhang ◽  
Xian Li Liu ◽  
Shu Cai Yang ◽  
Qi Zhang
Keyword(s):  
End Milling ◽  
Cutting Speed ◽  
End Mill ◽  
Ball End Mill ◽  
Flat Bottom ◽  
Good Surface ◽  
Complex Cavity ◽  
Cutter Design ◽  
Bottom Width ◽  
Curvature Interference

Complex cavity generally is machined in 3 axis or 3+2 axis machine tools, it has large amount of metal to be removed. For complex cavity machining, the cutting speed of ball end mill`s head point is zero, which makes its end milling ability poor; Torus cutter `s flat bottom width is wide, which causes curvature interference and concave-uncut. So this article designs a new kind of cutter for complex cavity roughing and semi-finishing, which can improve ball end mill`s poor end milling ability and decrease flat-end width. The simulation results show that the new cutter`s feasibility of machining complex cavity is better, and it can obviously reduce the amount of owe cutting compared with the torus cutter; At the same time, the new cutter can improve machining efficiency by 32.4% compared with the ball end mill, and good surface can also be generated.

On the Flexible Abrasive Tool for Nanofinishing of Complex Surfaces

2019 ◽  
Vol 18 (01) ◽  
pp. 157-166 ◽  
Author(s):  
Mithun Sarkar ◽  
V. K. Jain ◽  
Ajay Sidpara
Keyword(s):  
Surface Roughness ◽  
Corrosion Inhibitor ◽  
Abrasive Tool ◽  
End Mill ◽  
Complex Surfaces ◽  
Ball End Mill ◽  
Workpiece Surface ◽  
Abrasive Particles ◽  
Processing Step ◽  
Finishing Tool

Nanofinishing of complex surfaces is an important but costly processing step for many products for performing their functions satisfactorily. This paper deals with the development of a flexible abrasive tool for nanofinishing of complex surfaces. A flexible finishing tool similar to the ball end mill is developed by curing Polydimethylsiloxane (PDMS). A bowl-shaped copper workpiece is finished to nanometer surface roughness value. Different sizes of abrasive particles are used to reduce surface roughness value of the workpiece. A corrosion inhibitor is mixed with the abrasive slurry to protect the finished copper workpiece surface. A final surface roughness value of 50[Formula: see text]nm has been achieved with a variation up to 70[Formula: see text]nm on different locations of the bowl-shaped workpiece.

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