Theoretical Estimation of Machined Surface Profile Based on Cutting Edge Movement and Tool Orientation in Ball-nosed End Milling

CIRP Annals ◽  
2003 ◽  
Vol 52 (1) ◽  
pp. 49-52 ◽  
Author(s):  
Y. Mizugaki ◽  
K. Kikkawa ◽  
H. Terai ◽  
M. Hao ◽  
T. Sata
Keyword(s):  
End Milling ◽  
Surface Profile ◽  
Cutting Edge ◽  
Theoretical Estimation ◽  
Tool Orientation ◽  
Machined Surface

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.

Study on Cutting Temperature Modeling of Machined Workpiece in End Milling In-Situ TiB2/7050Al MMCs

2018 ◽  
Author(s):  
Yifeng Xiong ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Kunyang Lin
Keyword(s):  
Heat Source ◽  
Metal Cutting ◽  
End Milling ◽  
Great Influence ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Temperature Model ◽  
Machined Surface ◽  
Temperature Modeling

During metal cutting, it is well known that the cutting temperature has great influence on the machined surface integrity, especially on the residual stress and machining defects. At present, a lot of analytical modeling work has been done on the cutting temperature of tool, chips and workpiece machined by the side cutting edge during end milling process. To the workpiece surface machined by the bottom cutting edge, the study of temperature modeling is rarely reported. Besides, as a new kind of particulate metal matrix composites (MMCs) with improved mechanical and physical properties, the machining study of in-situ TiB2/7050Al MMCs is not many and no analytical temperature modeling of MMCs has been published up to now. Our study aims to establish an analytical cutting temperature model of workpiece machined by the bottom cutting edge in end milling in-situ TiB2/7050Al MMCs. In this model, the moving heat source method was applied. To meet the actual cutting process, the effect of heating time was also taken into account. With validation, the temperature model shows good agreement with experimental results. It was found that the heat partition ratio conducted from the shear plane heat source to the workpiece increased linearly as thermal number increased, due to the influence of increasing heat conducted into chip by the side cutting edge. The proposed cutting temperature model was of great significance for both the temperature modeling work of end milling and study of Al-MMCs.

Development of Magnetic Polishing for Micro Channel With a Ball-Nose-Shaped Tool

2013 ◽  
Author(s):  
Yusuke Takebayashi ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
Keiji Ogawa ◽  
Shreyes N. Melkote
Keyword(s):  
Machine Tool ◽  
End Milling ◽  
Surface Profile ◽  
Micro Channel ◽  
End Mill ◽  
Machined Surface ◽  
Micro Channels ◽  
Mems Technology ◽  
Micro Tool ◽  
Micro Total Analysis Systems

In recent years, a high quality and accurately manufactured surface is needed for micro channels for micro-TAS (micro-total analysis systems, a kind of MEMS technology) chips in medical fields. We demonstrated that the use of smaller machine tools is an effective method to reduce the environmental impact in the small parts manufacturing field. Then, in this report, we focus on magnetic polishing for micro channels with a ball-nose-shaped tool, integrating the end milling and polishing processes in a desktop-sized machine tool. The magnetic brush was formed by adhering a magnetic polishing paste, which was composed of abrasive grains (alumina, particle size 0.05 um), metallic particles (cast-iron, diameter 1–100 um), and solvating media (vegetal oil), to the tip (radius 2 mm) of the ball-nose-shaped tool, which was a permanent magnet and a prototype micro tool with a ball-nose end mill shape. We attempt to end mill and polish the surface of micro channels with a prototype magnetic tool and a desktop-sized machine tool. The quality of the machined surface is estimated with a high accuracy surface profile meter. As a result, it can be seen that the proposed method is effective to machine and finish the micro channel surface for micro-TAS chips.

scholarly journals Micro-End-Milling with Small Diameter Left Hand Helical Tool for High Quality Vertical Wall Machining

2019 ◽  
Vol 13 (5) ◽  
pp. 639-647
Author(s):  
Keiji Ogawa ◽  
Takumi Imada ◽  
Haruki Kino ◽  
Heisaburo Nakagawa ◽  
Hitomi Kojima ◽  
...  
Keyword(s):  
High Speed ◽  
End Milling ◽  
Vertical Wall ◽  
Small Diameter ◽  
Cutting Edge ◽  
End Mill ◽  
High Quality ◽  
Machined Surface ◽  
Left Hand ◽  
Micro End Milling

The demand for micro-end-milling for products in fields such as the medical, optical, and electronics industry is increasing. However, when machining with a small diameter end-mill (micro-end-mill) with diameters such as 0.5 mm, the rigidity of the tool itself is low; hence, the cutting conditions must be set to low values to achieve stable machining. Therefore, we examined various cutting phenomena that occur during actual machining processes to achieve high machining accuracy, high finished-surface quality, and long tool life. Some studies on micromachining achieved high accuracy, high-grade machining by considering the cutting phenomena. In previous papers, we dealt with the side-cutting phenomena in micro-end-milling of hardened die steels using a high-speed air-turbine spindle with rolling bearing. Cutting experiments were carried out by measuring the cutting force and flank wear of a cutting tool to investigate the difference in cutting phenomena caused by cutting direction in high-speed micro-end-milling. Observation of the machined surface and measurement of the profile of the cutting edge and machined surface were demonstrated. It was revealed that machining quality in high-speed up-cut milling was better than that in down-cut milling. Shoulder cutting, in which both peripheral and bottom cutting edges act simultaneously on the workpiece, was also investigated. A novel small diameter end-mill with left-hand helical tool with right-hand cut was developed to avoid damaging the cutting edge in the initial cutting stage. In the present study, high-quality shoulder cutting of a vertical wall using the new tool was proposed and demonstrated.

scholarly journals Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4V

Materials ◽  
2021 ◽  
Vol 14 (23) ◽  
pp. 7143
Author(s):  
Anshan Zhang ◽  
Caixu Yue ◽  
Xianli Liu ◽  
Steven Y. Liang
Keyword(s):  
Formation Mechanism ◽  
Complex Geometry ◽  
End Milling ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Milling Process ◽  
Cutting Edge ◽  
Machined Surface ◽  
Surface Machining ◽  
Feed Direction

Ball-end cutters are widely used for machining the parts of Ti-6Al-4V, which have the problem of poor machined surface quality due to the low cutting speed near the tool tip. In this paper, through the experiments of inclined surface machining in different feed directions, it is found that the surface adhered damages will form on the machined surface under certain tool postures. It is determined that the formation of surface adhered damage is related to the material adhesion near the cutting edge and the cutting-into/out position within the tool per-rotation cycle. In order to analyze the cutting-into/out process more clearly under different tool postures, the projection models of the cutting edge and the cutter workpiece engagement on the contact plane are established; thus, the complex geometry problem of space is transformed into that of plane. Combined with the case of cutting-into/out, chip morphology, and surface morphology, the formation mechanism of surface adhered damage is analyzed. The analysis results show that the adhered damage can increase the height parameters Sku, Sz, Sp, and Sv of surface topographies. Sz, Sp, and Sv of the normal machined surface without damage (Sku ≈ 3) are about 4–6, 2–3, and 2–3 μm, while Sz, Sp, and Sv with adhered damage (Sku > 3) can reach about 8–20, 4–14, and 3–6 μm in down-milling and 10–25, 7–18, and 3–7 μm in up-milling. The feed direction should be selected along the upper left (Q2: β∈[0°, 90°]) or lower left (Q3: β∈[90°, 180°]) to avoid surface adhered damage in the down-milling process. For up-milling, the feed direction should be selected along the upper right (Q1: β∈(−90°, 0°]) or upper left (Q2: β∈[0°, 90°)).

An Enhanced End Milling Surface Texture Model Including the Effects of Radial Rake and Primary Relief Angles

1994 ◽  
Vol 116 (2) ◽  
pp. 166-174 ◽  
Author(s):  
S. N. Melkote ◽  
A. R. Thangaraj
Keyword(s):  
Surface Roughness ◽  
Surface Texture ◽  
End Milling ◽  
Three Dimensional ◽  
Roughness Parameter ◽  
Surface Profile ◽  
Dimensional Structure ◽  
Machined Surface ◽  
Texture Model ◽  
Parameter Values

An enhanced surface texture model for predicting the two- and three-dimensional structure of the surface generated by the end cutting edges on the bottom of an end mill is presented. This model includes the effects of the radial rake and the primary end tooth relief angles which have been neglected in the models available to date. Non-ideal effects such as cutter runout and back-cutting are explicitly modeled. An algorithm to simulate the two- and three-dimensional milled surface is presented. It is shown that the main effect of the radial rake and the primary end tooth relief angles is to increase the surface roughness parameter values. The effectiveness of the enhanced model in accurately capturing the major features of the machined surface texture and in closely predicting the roughness parameter values is demonstrated through experiments and model simulations. It is shown that the enhanced model predicts both the shape of the surface profile and the surface roughness parameters more accurately than the existing models in the literature.

Numerical Simulation of Machined Surface Topography and Roughness in Milling Process

2005 ◽  
Vol 128 (1) ◽  
pp. 96-103 ◽  
Author(s):  
Tong Gao ◽  
Weihong Zhang ◽  
Kepeng Qiu ◽  
Min Wan
Keyword(s):  
Surface Topography ◽  
End Milling ◽  
Equation System ◽  
Milling Process ◽  
Cutting Edge ◽  
Machined Surface ◽  
Ball End Milling ◽  
Starting Point ◽  
Trajectory Equation ◽  
End Milling Process

Machined surface topography is very critical since it directly affects the surface quality, especially the surface roughness. Based on the trajectory equations of the cutting edge relative to the workpiece, a new method is developed for the prediction of machined surface topography. This method has the advantage of simplicity and is a mesh-independent direct computing method over the traditional interpolation scheme. It is unnecessary to discretize the cutting edge or to mesh the workpiece. The topography value of any point on the machined surface can be calculated directly, and the spindle runout can be taken into account. The simulation of machined surface topography is successfully carried out for both end and ball-end milling processes. In the end milling process, a fast convergence of solving the trajectory equation system by the Newton-Raphson method can be ensured for topography simulation at any node on the machined surface thanks to the appropriate choice of the starting point. In the ball-end milling process, this general algorithm is applicable to any machined surface. Finally, the validity of the method is demonstrated by several simulation examples. Simulation results are compared to experimental ones, and a good agreement is obtained.

Sign in / Sign up

Export Citation Format

Share Document