scholarly journals Study on chip removal mechanism of PCD ball-end milling (1st report) cutting simulation by orthogonal cutting

2020 ◽  
Vol 8 (1) ◽  
pp. 486-495
Author(s):  
Peerapong Kasuriya ◽  
Takeshi Watanabe ◽  
Takashi Goto ◽  
Masahiko Jin
Keyword(s):  
End Milling ◽  
Orthogonal Cutting ◽  
Removal Mechanism ◽  
Cutting Simulation ◽  
Ball End Milling ◽  
On Chip ◽  
Chip Removal

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.

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.

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.

scholarly journals Research on chip removal mechanism of pulse fluid negative pressure in deep hole machining

2021 ◽  
Vol 1748 ◽  
pp. 062014
Author(s):  
Xiao Zhang ◽  
Zhen Dong ◽  
Zhi Bing Zhang ◽  
Fang Ping Yao
Keyword(s):  
Negative Pressure ◽  
Deep Hole ◽  
Removal Mechanism ◽  
On Chip ◽  
Hole Machining ◽  
Chip Removal

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.

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