Differences and similarities between the induced residual stresses after ball end milling and orthogonal cutting of Ti–6Al–4V

2015 ◽  
Vol 226 ◽  
pp. 15-24 ◽  
Author(s):  
Dennis Nespor ◽  
Berend Denkena ◽  
Thilo Grove ◽  
Volker Böß
Keyword(s):  
Residual Stresses ◽  
End Milling ◽  
Orthogonal Cutting ◽  
Ball End Milling

Analytical Prediction of Stability Lobes in Ball End Milling

1999 ◽  
Vol 121 (4) ◽  
pp. 586-592 ◽  
Author(s):  
Y. Altıntas¸ ◽  
E. Shamoto ◽  
P. Lee ◽  
E. Budak
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Transformation Method ◽  
Quadratic Equation ◽  
Analytical Prediction ◽  
Force Coefficient ◽  
Ball End Milling ◽  
Stability Lobes

The paper presents an analytical method to predict stability lobes in ball end milling. Analytical expressions are based on the dynamics of ball end milling with regeneration in the uncut chip thickness, time varying directional factors and the interaction with the machine tool structure. The cutting force coefficients are derived from orthogonal cutting data base using oblique transformation method. The influence of cutting coefficients on the stability is investigated. A computationally efficient, an equivalent average cutting force coefficient method is developed for ball end milling. The prediction of stability lobes for ball end milling is reduced to the solution of a simple quadratic equation. The analytical results agree well with the experiments and the computationally expensive and complex numerical time domain simulations.

Residual Stresses Modelling of End Milling Process Using Numerical and Experimental Methods

2020 ◽  
Vol 978 ◽  
pp. 106-113
Author(s):  
Marimuthu K. Prakash ◽  
Kumar C.S. Chethan ◽  
Prasada H.P. Thirtha
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
End Milling ◽  
Orthogonal Cutting ◽  
Milling Process ◽  
Parent Material ◽  
Machining Processes ◽  
Element Analysis ◽  
1045 Steel ◽  
Cutting Model

Machining has been one of the most sort of process for realizing different products. It has significant role in the value additions process. Machining is one of the production process where material is removed from the parent material to realize the final part or component. Among machining, the well known machining processes are turning, milling, shaping, grinding and non-conventional machining processes like electric discharge machining, ultrasonic machining, chemical machining etc. The fundamental of all these processes being material removal in the form of chips using a tool either in contact or not in contact. In the present work, milling is being taken for study Finite element analysis is being used as a tool to understand the different phenomenon that underlies the machining processes. Of late, the machining induced residual stresses is of great interest to the researchers since the residual stresses have an impact on the functional performances. The present work is to model the milling process to predict the forces and residual stresses using finite element method. Unlike many researchers, the authors have attempted to develop oblique cutting model rather than an orthogonal cutting model. The present work was carried out on AISI 1045 steel.

scholarly journals Residual Stresses Analysis in Ball end Milling of Nickel-Based Superalloy Inconel 718

2017 ◽  
Vol 20 (6) ◽  
pp. 1681-1689 ◽  
Author(s):  
Junteng Wang ◽  
Dinghua Zhang ◽  
Baohai Wu ◽  
Ming Luo
Keyword(s):  
Residual Stresses ◽  
Inconel 718 ◽  
End Milling ◽  
Ball End Milling ◽  
Nickel Based Superalloy

scholarly journals 3D Heat Transfer Analysis for a Hybrid Approach to Predict Residual Stresses After Ball-End Milling

2011 ◽  
Vol 19 ◽  
pp. 125-131 ◽  
Author(s):  
N. Guillemot ◽  
M. Winter ◽  
A. Souto-Lebel ◽  
C. Lartigue ◽  
R. Billardon
Keyword(s):  
Heat Transfer ◽  
Residual Stresses ◽  
End Milling ◽  
Hybrid Approach ◽  
Heat Transfer Analysis ◽  
Ball End Milling

scholarly journals Mechanics and Dynamics of Ball End Milling

1998 ◽  
Vol 120 (4) ◽  
pp. 684-692 ◽  
Author(s):  
Y. Altıntas¸ ◽  
P. Lee
Keyword(s):  
Time Domain ◽  
Transfer Functions ◽  
End Milling ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Milling Process ◽  
Body Motion ◽  
Ball End Milling ◽  
Cutting Model ◽  
End Milling Process

Mechanics and dynamics of cutting with helical ball end mills are presented. The helical ball end mill attached to the spindle is modelled by orthogonal structural modes in the feed and normal directions at the tool tip. For a given cutter geometry, the cutting coefficients are transformed from an orthogonal cutting data base using an oblique cutting model. The three dimensional swept surface by the cutter is digitized using the true trochoidal kinematics of ball end milling process in time domain. The dynamically regenerated chip thickness, which consists of rigid body motion of the tooth and structural displacements, is evaluated at discrete time intervals by comparing the present and previous tooth marks left on the finish surface. The process is simulated in time domain by considering the instantaneous regenerative chip load, local cutting force coefficients, structural transfer functions and the geometry of ball end milling process. The proposed model predicts cutting forces, surface finish and chatter stability lobes, and is verified experimentally under both static and dynamic cutting conditions.

scholarly journals Research on Homogenization and Surface Integrity of Ti-6Al-4V Alloy by Longitudinal-Torsional Coupled Ultrasonic Vibration Ball-End Milling

2018 ◽  
Author(s):  
Wanfei Ren ◽  
Jinkai Xu ◽  
Jieqiong Lin ◽  
Zhanjiang Yu ◽  
Peng Yu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Residual Stresses ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
High Frequency ◽  
End Milling ◽  
Cutting Speed ◽  
Ball End Milling ◽  
Average Value ◽  
Cutting Experiments

This paper aims to study the surface homogenization and integrity of Ti-6Al-4V alloy by longitudinal-torsional coupled ultrasonic vibration assisted ball-end milling. A method of continuous processing between the flat surface and freeform surface connection is proposed by using ultrasonic vibration assisted ball-end precision milling, during this process, it is not necessary to exchange the cutting tool. The way has been explored for changing the homogenization of surface on Ti-6Al-4V by ultrasonic vibration-assisted milling (UVAM). Cutting experiments employing three parameters, cutting speed, feed rate and depth of cut and two types of machining forms using ball-end milling with UVAM and conventional milling (CM) respectively. The high frequency cutting force, finished surface roughness, topography and residual stresses on the surface and tool wear have been measured by advanced instruments. Particularly, adopting the high frequency cutting force measurement system, it is concluded cutting force in ball-end milling decreased significantly using UVAM as against CM. Moreover, the surface roughness by UVAM with ball-end milling is much better than the CM at a high cutting speed. However, an opposite trend is observed at a low cutting speed. Especially, there is a steep decrease from Ra 0.828 μm average value at 4000 rpm to Ra 0.129 μm average value at 5000 rpm. At the same time, the homogenization of surface roughness and residual stresses decrease significantly in UVAM as compared to which in CM when taking the transversal-longitudinal ratio into consideration. Cutting experiments and measuring results are demonstrated the validity and feasibility of UVAM with ball-end milling, and this method enjoys significant advantages compared to CM process.

Analysis of Cutting Forces in Helical Ball-End Milling Based on Coordinate Conversion

2010 ◽  
Vol 139-141 ◽  
pp. 917-920
Author(s):  
Wei Guo Wu ◽  
Gui Cheng Wang ◽  
Chun Gen Shen
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Orthogonal Cutting ◽  
Milling Process ◽  
Global Coordinate System ◽  
Ball End Milling ◽  
Oblique Cutting ◽  
Milling Operations ◽  
End Mills

In this work, the prediction and analysis of cutting forces in helical ball-end milling operations is presented. The cutting forces model for helical end-mills is based on the oblique cutting theory and the geometric relations of the ball-end milling process. The helical flutes are divided into small differential oblique cutting edge segments. According to the transformation relationship between the local and global coordinate system of the cutter, the differential cutting force of cutting element is obtained by two coordinate conversions from the orthogonal cutting force. The total cutting force of helical ball-end milling is the sum of the cutting force in whole cutting field of the miller. As a result, the predicted cutting forces show an agreement with the values from the cutting experiments.

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