Influences of the workpiece material and the tool-surface engagement (TSE) on surface finishing when ball-end milling

2022 ◽  
Vol 75 ◽  
pp. 219-231
Author(s):  
Igor Basso ◽  
Rodrigo Voigt ◽  
Alessandro Roger Rodrigues ◽  
Felipe Marin ◽  
Adriano Fagali de Souza ◽  
...  
2007 ◽  
Vol 189 (1-3) ◽  
pp. 85-96 ◽  
Author(s):  
M. Fontaine ◽  
A. Devillez ◽  
A. Moufki ◽  
D. Dudzinski

1999 ◽  
Author(s):  
Hsi-Yung (Steve) Feng ◽  
Ning Su

Abstract The prediction and optimization of cutting forces in the finishing machining of 3D plane surfaces using ball-end milling are presented in this paper. The cutting force model is developed based on the mechanistic modeling approach. This improved model is able to accurately predict the cutting forces for non-horizontal and cross-feed cutter movements typical in 3D finishing ball-end milling. Optimization of the cutting forces is used to determine both the tool path and the maximum feed rate in 3D plane surface finishing machining. The objective is to achieve highest machining efficiency and to ensure product quality. Experimental results have shown that the cutting force model gives excellent predictions of cutting forces in 3D finishing ball-end milling. The feasibility of the integrated process planning method has been demonstrated through the establishment of optimized process plans for the finishing machining of 3D plane surfaces.


2017 ◽  
Vol 261 ◽  
pp. 299-304 ◽  
Author(s):  
Balázs Mikó ◽  
Balázs Tóth ◽  
Bálint Varga

In case of free form surface milling the quality of the manufacturing is described by the accuracy of the shape and the surface roughness. The 3D surface finishing milling by ball-end milling cutter is one of the most often used machining technologies. In case of ball-end milling the surface roughness can be described theoretically based on the tool diameter and the density of the tool path, but the experience shows than other parameters have effect on the surface roughness. In the article the effect of the different cutting parameters, like feed (fz), depth of cut (ap) and width of cut (ae), is presented in case of plane surface, and the surface roughness is compared with the theoretical roughness, and an estimation method is presented.


2007 ◽  
Vol 189 (1-3) ◽  
pp. 73-84 ◽  
Author(s):  
M. Fontaine ◽  
A. Moufki ◽  
A. Devillez ◽  
D. Dudzinski

2015 ◽  
Vol 15 (3) ◽  
pp. 293-300 ◽  
Author(s):  
Nandkumar N. Bhopale ◽  
Nilesh Nikam ◽  
Raju S. Pawade

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.


2000 ◽  
Vol 123 (3) ◽  
pp. 369-379 ◽  
Author(s):  
Rixin Zhu ◽  
Shiv G. Kapoor ◽  
Richard E. DeVor

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.


2016 ◽  
Vol 693 ◽  
pp. 788-794
Author(s):  
Xiao Xiao Chen ◽  
Jun Zhao

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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