Ball end milling mechanistic model based on a voxel-based geometric representation and a ray casting technique

2013 ◽  
Vol 15 (3) ◽  
pp. 338-347 ◽  
Author(s):  
Soungjin J. Wou ◽  
Yung C. Shin ◽  
Hazim El-Mounayri
Keyword(s):  
End Milling ◽  
Mechanistic Model ◽  
Geometric Representation ◽  
Ray Casting ◽  
Ball End Milling ◽  
Casting Technique ◽  
Model Based

Generalized Mechanistic Force System Model of Ball-End Milling for Sculpture Surface Machining

2001 ◽  
Author(s):  
Ismail Lazoglu
Keyword(s):  
End Milling ◽  
Mechanistic Model ◽  
Milling Process ◽  
Force System ◽  
Workpiece Surface ◽  
Surface Machining ◽  
Ball End Milling ◽  
End Milling Process ◽  
Validation Experiments ◽  
Good Agreement

Abstract In this paper, a new mechanistic model is developed for the prediction of cutting force system in ball-end milling process. The key feature of the model includes the ability to calculate the workpiece / cutter intersection domain automatically for a given cutter location (CL) file, cutter and workpiece geometries. Moreover, an analytical approach is used to determine the instantaneous chip load and cutting forces. The model also employs a Boolean approach for given cutter, workpiece geometries, and the CL file in order to determine the surface topography and scallop height variations along the workpiece surface which can be visualized in 3-D. Some of the typical results from the model validation experiments performed on Ti-6A1-4V are also reported in the paper. Comparisons of the predicted and measured forces as well as the surface topographies show good agreement.

scholarly journals Modified Mechanistic Model Based on Gaussian Process Adjusting Technique for Cutting Force Prediction in Micro-End Milling

2019 ◽  
Vol 2019 ◽  
pp. 1-12
Author(s):  
Xiaoping Liao ◽  
Zhenkun Zhang ◽  
Kai Chen ◽  
Kang Li ◽  
Junyan Ma ◽  
...  
Keyword(s):  
Gaussian Process ◽  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Mechanistic Model ◽  
Machining Process ◽  
Mechanistic Models ◽  
Machining Processes ◽  
Model Based ◽  
Micro End Milling

Micro-end milling is in common use of machining micro- and mesoscale products and is superior to other micro-machining processes in the manufacture of complex structures. Cutting force is the most direct factor reflecting the processing state, the change of which is related to the workpiece surface quality, tool wear and machine vibration, and so on, which indicates that it is important to analyze and predict cutting forces during machining process. In such problems, mechanistic models are frequently used for predicting machining forces and studying the effects of various process variables. However, these mechanistic models are derived based on various engineering assumptions and approximations (such as the slip-line field theory). As a result, the mechanistic models are generally less accurate. To accurately predict cutting forces, the paper proposes two modified mechanistic models, modified mechanistic models I and II. The modified mechanistic models are the integration of mathematical model based on Gaussian process (GP) adjustment model and mechanical model. Two different models have been validated on micro-end-milling experimental measurement. The mean absolute percentage errors of models I and II are 7.76% and 6.73%, respectively, while the original mechanistic model’s is 15.14%. It is obvious that the modified models are in better agreement with experiment. And model II performs better between the two modified mechanistic models.

Parameter Optimization of Ball End Milling Process on Inconel 718 Using RSM and TLBO Algorithm

2015 ◽  
Vol 15 (3) ◽  
pp. 293-300 ◽  
Author(s):  
Nandkumar N. Bhopale ◽  
Nilesh Nikam ◽  
Raju S. Pawade
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Tool Path ◽  
End Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Ball End Milling

AbstractThis paper presents the application of Response Surface Methodology (RSM) coupled with Teaching Learning Based Optimization Technique (TLBO) for optimizing surface integrity of thin cantilever type Inconel 718 workpiece in ball end milling. The machining and tool related parameters like spindle speed, milling feed, axial depth of cut and tool path orientation are optimized with considerations of multiple response like deflection, surface roughness, and micro hardness of plate. Mathematical relationship between process parameters and deflection, surface roughness and microhardness are found out by using response surface methodology. It is observed that after optimizing the process that at the spindle speed of 2,000 rpm, feed 0.05 mm/tooth/rev, plate thickness of 5.5 mm and 15° workpiece inclination with horizontal tool path gives favorable surface integrity.

Mechanistic Modeling of the Ball End Milling Process for Multi-Axis Machining of Free-Form Surfaces

2000 ◽  
Vol 123 (3) ◽  
pp. 369-379 ◽  
Author(s):  
Rixin Zhu ◽  
Shiv G. Kapoor ◽  
Richard E. DeVor
Keyword(s):  
End Milling ◽  
Chip Thickness ◽  
Mechanistic Modeling ◽  
Free Form ◽  
Surface Geometry ◽  
Workpiece Surface ◽  
Ball End Milling ◽  
Modeling Approach ◽  
Free Form Surfaces ◽  
Cutting Point

A mechanistic modeling approach to predicting cutting forces is developed for multi-axis ball end milling of free-form surfaces. The workpiece surface is represented by discretized point vectors. The modeling approach employs the cutting edge profile in either analytical or measured form. The engaged cut geometry is determined by classification of the elemental cutting point positions with respect to the workpiece surface. The chip load model determines the undeformed chip thickness distribution along the cutting edges with consideration of various process faults. Given a 5-axis tool path in a cutter location file, shape driving profiles are generated and piecewise ruled surfaces are used to construct the tool swept envelope. The tool swept envelope is then used to update the workpiece surface geometry employing the Z-map method. A series of 3-axis and 5-axis surface machining tests on Ti6A14V were conducted to validate the model. The model shows good computational efficiency, and the force predictions are found in good agreement with the measured data.

Geometrical Modeling of Tool-Workpiece Contact Zone and Chip Formation in Finish Ball End Milling Process with Tool Inclination Angles

2016 ◽  
Vol 693 ◽  
pp. 788-794
Author(s):  
Xiao Xiao Chen ◽  
Jun Zhao
Keyword(s):  
Contact Zone ◽  
Measurement Method ◽  
End Milling ◽  
Milling Process ◽  
Ball End Milling ◽  
Geometrical Modeling ◽  
Section Area ◽  
Inclination Angles ◽  
Area And Perimeter ◽  
End Milling Process

The tool-workpiece contact zone is an important issue in the ball end milling process. This paper investigated the effects of tool inclination angles on the tool-workpiece contact zone, and variations of the cutting section area and perimeter with the increasing tilt and lead angles were also analyzed by geometrical modeling and measurement method for ball end milling process. The appropriate tool inclination angles, which could avoid the extrusion and friction between tool tip and the uncut materials, shorten the loading time on the cutting flute, and decrease the maximum cutting forces, could be preferentially selected according to the distribution characteristics of the tool-workpiece contact zone and the variations of the cutting section area and perimeter corresponding to various tool postures.

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