The simulation of cutting force of free-form surface machining with ball-end milling cutter

In this paper, a process model-based approach has been proposed for monitoring and fault diagnosis in the multi-axis ball end milling process. Besides its ability to deal with complex cutting geometry in free-form surface machining, the method has the capability of not only detecting the presence but also estimating the magnitudes of faults, which include flute chipping, breakage and spindle/cutter axes runout. A threshold-based fault detection method is developed based on the analysis of harmonic power distribution in the cutting force signal. A genetic algorithm approach is used to search and determine the fault pattern and magnitudes. The new approach is validated through both constant cross-section cut and free-form surface machining tests on 1018 steel.

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Dynamics Characteristics of High Speed Ball-End Milling Cutter for Machining Hardened Steel

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.455.127 ◽

2010 ◽

Vol 455 ◽

pp. 127-131

Author(s):

Bin Jiang ◽

Min Li Zheng ◽

Jun Zhou ◽

D.H. Xia

Keyword(s):

Cutting Force ◽

High Speed ◽

End Milling ◽

Hardened Steel ◽

Milling Cutter ◽

High Speed Milling ◽

Ball End Milling ◽

Modal Characteristics ◽

Dynamic Cutting Force ◽

Cutting Vibration

In order to depress cutter vibration caused by high hardness and periodic change of cutting force in high speed milling complex surface, investigated the modal characteristics of ball-end milling cutter through the modal analysis and transient analysis. Using the models of dynamic cutting force and cutting vibration, acquired dynamics characteristics of high speed ball-end milling cutter by the spectrum analysis of dynamic cutting force, simulation analysis of cutting vibration and experiment of high speed milling hardened steel. Results indicate that high speed ball-end milling energy concentrates in few special frequencies, the rotational speed and the numbers of cutter teeth determine the fundamental frequency. High speed ball-end milling cutter easily makes radial bending vibration by the lower modal characteristics, the overhang and inclination angle of cutter affect its dynamics characteristics significantly, and the modal parameters and vibration model of cutter acquired by step response method have higher credibility.

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Cutting Force and Nonlinear Chatter Stability of Ball-end Milling Cutter

10.21203/rs.3.rs-707239/v1 ◽

2021 ◽

Author(s):

Ce Zhang ◽

Changyou LI ◽

Mengtao Xu ◽

Guo Yao ◽

Zhendong Liu ◽

...

Keyword(s):

Cutting Force ◽

Degrees Of Freedom ◽

End Milling ◽

Force Model ◽

Milling Force ◽

Milling Cutter ◽

Ball End Milling ◽

Milling Chatter ◽

Milling Force Model ◽

Three Degrees Of Freedom

Abstract Ball-end milling cutters are one of the most widely used cutters in the automotive, aerospace, die and machine parts industries. In addition, milling chatter will reduce the surface quality and production efficiency, resulting in noise. It is particularly important to model the cutting force and analyze the flutter stability of ball-end milling cutters. In this paper, a simplified milling force model of ball-end milling cutter with three degrees of freedom was established based on Merchant bevel cutting theory. The model simplified the milling force coefficient. The expressions of instantaneous milling area considering the vibration displacements in X, Y and Z directions were derived. The nonlinear dynamic cutting force model of ball-end milling cutter with three degrees of freedom was established. The nonlinear chatter vibration mechanical model of ball-end milling cutter with three degrees of freedom was established by introducing the time delay term, the stability analysis is carried out by time domain simulation. The proposed models were experimentally verified.

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Optimization of free-form surface machining using parallel planes strategy and torus milling cutter

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405416640175 ◽

2016 ◽

Vol 232 (2) ◽

pp. 240-250 ◽

Cited By ~ 3

Author(s):

Jean-Max Redonnet ◽

Alejandro Gamboa Vázquez ◽

Alberto Traslosheros Michel ◽

Stéphane Segonds

Keyword(s):

End Milling ◽

Free Form ◽

End Mill ◽

Machining Time ◽

Surface Machining ◽

End Mills ◽

Free Form Surface ◽

Optimization Methodology ◽

Free Form Surfaces ◽

Industrial Part

Machining by parallel planes is a widely used strategy for end-milling of free-form surfaces on 3-axis numerically controlled machines. In industry, this type of machining is generally performed with a hemispherical tool. However, numerous studies have shown the benefits of torus-end mills over ball-end or flat-end mills. More than anything, the machining direction has much influence on productivity while using a torus-end mill. In this context, the choice of the machining direction is of paramount importance when using a torus-end mill in the machining of free-form surfaces. This paper presents an optimization of part machining direction allowing the machining time to be minimized while respecting the maximum imposed scallop height. This optimization methodology is then applied to an industrial part and measurements are performed on this part. The study highlights the interest of optimizing the machining direction and the benefits that can be drawn with respect to machining using a non-optimized direction.

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Research on Instantaneous Cutting Force of High Speed Ball-End Milling Cutter

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.188.277 ◽

2011 ◽

Vol 188 ◽

pp. 277-282 ◽

Cited By ~ 1

Author(s):

Chang Xing Qi ◽

Bin Jiang ◽

Min Li Zheng ◽

Y.J. Yang ◽

P. Sun

Keyword(s):

Cutting Force ◽

High Speed ◽

End Milling ◽

Cutting Speed ◽

Cutting Process ◽

Energy Concentration ◽

Milling Cutter ◽

High Speed Milling ◽

Ball End Milling ◽

The Impact

For the instability of ball-end milling cutter in high speed milling, instantaneous cutting process of high speed milling hardened steel was studied. The model of instantaneous cutting layer parameters of high speed ball-end cutter was established, and the influence of cutting speed and inclination angles on instantaneous cutting layer parameters were obtained. Using the model, instantaneous cutting force was studied, and high speed milling experiment was processed. Results show that the increase of cutting speed makes the change rate of cutting layer parameters increasing, leads to the energy concentration in cutting process, and increases the impact on milling cutter. The increase of inclination angle makes the instantaneous cutting layer parameters show a trend of decrease and the decrease of cutting thickness more rapidly, which caused instantaneous unit cutting force to increase and the instantaneous main cutting force appears increasing trend, and the cutting process become unstable.

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

Journal of Manufacturing Science and Engineering ◽

10.1115/1.1369357 ◽

2000 ◽

Vol 123 (3) ◽

pp. 369-379 ◽

Cited By ~ 85

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.

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Tool Path Generation for Five-Axis Controlled Machining of Free-Form Surface Using Barrel Tool: Control of Contact Point on Cutting Edge

JSME 2020 Conference on Leading Edge Manufacturing/Materials and Processing ◽

10.1115/lemp2020-8539 ◽

2020 ◽

Author(s):

Tomonobu Suzuki ◽

Koichi Morishige

Keyword(s):

Tool Path ◽

Contact Point ◽

Cutting Edge ◽

Free Form ◽

End Mill ◽

Ball End Mill ◽

Surface Machining ◽

Free Form Surface ◽

The Cost ◽

Five Axis

Abstract This study aimed to improve the efficiency of free-form surface machining by using a five-axis controlled machine tool and a barrel tool. The barrel tool has cutting edges, with curvature smaller than the radius, increasing the pick feed width compared with a conventional ball end mill of the same tool radius. As a result, the machining efficiency can be improved; however, the cost of the barrel tool is high and difficult to reground. In this study, a method to obtain the cutting points that make the cusp height below the target value is proposed. Moreover, a method to improve the tool life by continuously and uniformly changing the contact point on the cutting edge is proposed. The usefulness of the developed method is confirmed through machining simulations.

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Machining of Carbon Fibre-Reinforced Silicon-Ccarbide Composites

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.59.51 ◽

2008 ◽

Vol 59 ◽

pp. 51-54 ◽

Cited By ~ 5

Author(s):

Dirk Biermann ◽

T. Jansen ◽

M. Feldhoff

Keyword(s):

Silicon Carbide ◽

Carbon Fibre ◽

Drill Hole ◽

Free Form ◽

Surface Machining ◽

Free Form Surface ◽

Hole Machining

A growing demand for fibre-reinforced ceramics necessitates effective ways for machining these materials. In this paper, different tool concepts are presented for an efficient machining of carbon fibre-reinforced silicon carbide. Drill hole machining, slot machining and first investigations of free-form surface machining are presented.

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