A Flexible Ball-End Milling System Model for Cutting Force and Machining Error Prediction

1996 ◽  
Vol 118 (4) ◽  
pp. 461-469 ◽  
Author(s):  
Hsi-Yung Feng ◽  
Chia-Hsiang Menq
Keyword(s):  
Cutting Forces ◽  
Present Model ◽  
End Milling ◽  
System Model ◽  
Rigid System ◽  
Ball End Milling ◽  
Flexible System ◽  
Machining Errors ◽  
Chip Geometry ◽  
Cutting System

This paper presents a flexible system model for the prediction of cutting forces and the resulting machining errors in the ball-end milling process. Unlike the previously developed rigid system model, the present model takes into account the instantaneous and regenerative feedback of cutting system deflections to establish the chip geometry in the cutting force calculation algorithm. The deflection-dependent chip geometry is identified by using an iterative procedure to balance the cutting forces and the associated cutting system deflections. A series of steady state 3D cross-feed ball-end milling cuts were performed to validate the capability of the present model in predicting the cutting forces and the resulting machining errors. It is shown that the flexible system model gives significantly better predictions of the cutting forces than the rigid system model. Good agreement between the predicted and measured machining errors is demonstrated for the simple surfaces generated by horizontal cuts.

An Improved Method for Cutting Force and Surface Error Prediction in Flexible End Milling Systems

1986 ◽  
Vol 108 (4) ◽  
pp. 269-279 ◽  
Author(s):  
J. W. Sutherland ◽  
R. E. DeVor
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
System Model ◽  
Machining Processes ◽  
Force System ◽  
Surface Error ◽  
Rigid System ◽  
Load Model ◽  
Flexible System ◽  
Chip Load

As more emphasis is placed on quality and productivity in manufacturing, it becomes necessary to develop models that more accurately describe the performance of machining processes. An improved model for the prediction of the cutting force system and surface error in end milling has been developed and has been implemented on the computer. This enhanced model takes into account the effect of system deflections on the chip load, and solves for the chip load that balances the cutting forces and the resulting system deflections. Such a model allows for the evaluation of cuts in which deflections significantly effect the chip load. The flexible system model predictions of forces and surface error are compared against both measured and rigid system model-predicted values associated with the machining conditions for experiments performed on the 390 casting aluminum alloy. It is shown that the enhanced chip load model gives predictions of both cutting force signatures and surface error profiles that are significantly better than the rigid system chip load model developed previously. The fact that system deflections temper the effects of runout, and reduce both peak cutting force and maximum surface error is demonstrated and discussed.

Study on Machining Error in Ball End Milling of Spherical Surface

2009 ◽  
Vol 407-408 ◽  
pp. 456-459 ◽  
Author(s):  
Hisataka Tanaka ◽  
Masahiko Sato ◽  
Hiroshi Yoshida ◽  
Satoki Ohta ◽  
Susumu Okamura
Keyword(s):  
End Milling ◽  
Spherical Surface ◽  
Position Angle ◽  
Machining Error ◽  
Machined Surface ◽  
Ball End Milling ◽  
Machining Errors ◽  
Series Of Experiments ◽  
Chip Geometry ◽  
Tool Deflections

This paper presents the results of a series of experiments performed to examine the validity of a theoretical analysis for evaluation of machining error in ball end milling of spherical surface. In the analysis, the trochoidal paths of cutting edges are considered in the evaluation of chip geometry. The cutting forces are evaluated based on the theory of oblique cutting. The machining errors resulting from cutting force induced tool deflections are calculated at various parts of the machined surface. The experiments are carried out at various cutting conditions for convex spherical surface, and the influences of cutting mode and milling position angle on machining error are examined.

Analysis of Cutting Forces and Machining Error in Ball End Milling of Cylindrical Surfaces

2011 ◽  
Vol 328-330 ◽  
pp. 560-564
Author(s):  
Ba Sheng Ouyang ◽  
Guo Xiang Lin ◽  
Yong Hui Tang
Keyword(s):  
Cutting Forces ◽  
End Milling ◽  
Cutting Conditions ◽  
Machining Error ◽  
Machined Surface ◽  
Convex Surfaces ◽  
Machining Errors ◽  
End Mills ◽  
Tool Deflections ◽  
Cutting Modes

Cutting forces and machining error in contouring of concave and convex surfaces using helical ball end mills are theoretically investigated. The cutting forces are evaluated based on the theory of oblique cutting. The machining errors resulting from the tool deflections due to these forces are evaluated at various points of the machined surface. The influence of various cutting conditions and cutting modes on machining error is investigated and discussed.

Analytical Convolution Model of Cutting Forces in 3-D Ball End Milling

2001 ◽  
Author(s):  
Richard Y. Chiou ◽  
Bing Zhao
Keyword(s):  
Cutting Force ◽  
Frequency Domain ◽  
Cutting Forces ◽  
End Milling ◽  
Force Model ◽  
Three Dimensional Model ◽  
Calculation Algorithm ◽  
Ball End Milling ◽  
Convolution Model ◽  
Force Calculation

Abstract This paper presents an analytical convolution model of dynamic cutting forces in ball end milling of 3-D plane surfaces. The model takes into account the instantaneous slope on a sculptured surface to establish the chip geometry in cutting force calculation algorithm. A three-dimensional model of cutting forces in ball end milling is presented in terms of material properties, cutting parameters, machining configuration, and tool/work geometry. Based on the relationship of the local cutting force, chip load and engaged boundary, the total cutting force model is established via the angle domain convolution integration of the local forces in the feed, cross feed, axial direction, and inclination angle. The convolution integral leads to a periodic function of cutting forces in the angle domain and an explicit expression of the dynamic cutting force components in the frequency domain. Following the theoretical analysis, experimental study is discussed to illustrate the implementation procedure for force identification, and frequency domain data are presented to verify the analytical results.

Experimental Investigation of the Effect of the Machine Kinematic Behavior on the Surface Topography and Roughness in High Speed Ball end Milling of the AISI4142 Steel

2021 ◽  
Author(s):  
Sai Lotfi ◽  
Belguith Rami ◽  
Baili Maher ◽  
Desseins Gilles ◽  
Bouzid Wassila
Keyword(s):  
Surface Topography ◽  
High Speed ◽  
End Milling ◽  
Experimental Investigations ◽  
Ball End Milling ◽  
Tool Paths ◽  
Stationary Zone ◽  
Machining Errors ◽  
Kinematic Behavior ◽  
Milling Tool

Abstract The analysis of the surface topography in ball end milling is an objective studied by many researchers, several methods were used and many combinations of cutting conditions and machining errors are considered. In the milling tool paths the trajectories presents a points of changing direction where the tool decelerates before and accelerates after respecting the velocity profiles of the machine. In this paper, we propose experimental investigations of the effect of the kinematic behavior of the machine tool on the surface quality. A poor topography and roughness are remarked on the deceleration and the acceleration zones compared to the stationary zone.

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