Curve-Curve Contact in 5-Axis NC Machining of Sculptured Surfaces Using Flat-End Cutter

2008 ◽  
Author(s):  
Hu Ran Liu
Keyword(s):  
Differential Geometry ◽  
End Milling ◽  
Curved Surface ◽  
Sculptured Surface ◽  
Sculptured Surfaces ◽  
End Mill ◽  
Ball End Mill ◽  
Ball End Milling ◽  
Swept Surface ◽  
Complicated Surface

The concept of “contact” in differential geometry is creatively applied into the machining of the sculptured surface; the contact principle of the machining of complicated surfaces is presented. The circumference circle of the cylindrical cutter instead of ball-end milling cutter is used to sweep the curved surface. This is the highly effective method. In this paper an innovative theory for machining complicated surface is presented. By using a flat-end mill instead of ball-end mill, and by adjusting the axis of cutter relative to the surface, the two surfaces, the swept surface and the required surface, have the same curvatures, up to as high as 3rd order. It shows how aspects of 5-axos machining can be achieved through 3-axis methods. This is useful as not all shops can afford 5-axis machining.

Surface-Curve Contact in 4-Axis NC Machining of Sculptured Surfaces Using Anural Cutter

2010 ◽  
Vol 37-38 ◽  
pp. 1372-1375
Author(s):  
Hu Ran Liu
Keyword(s):  
Differential Equation ◽  
Nc Machining ◽  
Sculptured Surfaces ◽  
End Mill ◽  
Ball End Mill ◽  
Axis Orientation ◽  
Milling Tool ◽  
Swept Surface ◽  
Complicated Surface ◽  
Surface Curve

This is the highly effective method. In this paper an innovative theory for machining complicated surface is presented. By using a anural milling tool instead of ball-end mill or the flat-ended tool, and by adjusting the axis of cutter relative to the surface, the two surfaces, the swept surface and the required surface, have the same curvatures, up to as high as 3rd order. Through the deduction of differential equation, some theory on partial touching between surfaces and surfaces when manufacturing has been explored. The problem of axis orientation under this condition has also been discussed clearly. The outside of the circular tool is a surface; the surface to be machined is a groove, which can be represented by its transverse line. In this case the problem is attributed to the contact between surface and curve.

Effect of Tool Tilting Angle on Tool Wear and Surface Roughness in Micro Ball End Milling

2011 ◽  
Vol 325 ◽  
pp. 606-611 ◽  
Author(s):  
Kazuya Hamaguchi ◽  
Yuji Kagata ◽  
Hiroo Shizuka ◽  
Koichi Okuda
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Flank Wear ◽  
End Milling ◽  
Depth Of Cut ◽  
End Mill ◽  
Ball End Mill ◽  
Ball End Milling ◽  
Tilting Angle ◽  
Radial Depth

This paper describes the effect of the tool tilting angle on the tool wear and the surface roughness in micro ball end milling. The cutting tests of hardened stainless steel were carried out by using of the micro ball end mill with radius of 100mm under the conditions of tilting angle from 0° to 45°. The spindle speed was fixed in a constant of 120,000 min-1. The feed per tooth, axial depth of cut and radial depth of cut were also fixed. The flank wear, the surface roughness and the cutting force were investigated. As a result, the maximum width of flank wear of the micro ball end mill tended to decrease with an increase in the tilting angle of spindle. The surface roughness became almost constant not depending on the tilting angle of the spindle.

The Milling Cutter Design and Simulation for Complex Cavity Machining

2014 ◽  
Vol 800-801 ◽  
pp. 465-469
Author(s):  
An Shan Zhang ◽  
Xian Li Liu ◽  
Shu Cai Yang ◽  
Qi Zhang
Keyword(s):  
End Milling ◽  
Cutting Speed ◽  
End Mill ◽  
Ball End Mill ◽  
Flat Bottom ◽  
Good Surface ◽  
Complex Cavity ◽  
Cutter Design ◽  
Bottom Width ◽  
Curvature Interference

Complex cavity generally is machined in 3 axis or 3+2 axis machine tools, it has large amount of metal to be removed. For complex cavity machining, the cutting speed of ball end mill`s head point is zero, which makes its end milling ability poor; Torus cutter `s flat bottom width is wide, which causes curvature interference and concave-uncut. So this article designs a new kind of cutter for complex cavity roughing and semi-finishing, which can improve ball end mill`s poor end milling ability and decrease flat-end width. The simulation results show that the new cutter`s feasibility of machining complex cavity is better, and it can obviously reduce the amount of owe cutting compared with the torus cutter; At the same time, the new cutter can improve machining efficiency by 32.4% compared with the ball end mill, and good surface can also be generated.

Voxel Based Cutting Force Simulation of Ball End Milling Considering Cutting Edge Around Center Web

2018 ◽  
Author(s):  
Isamu Nishida ◽  
Takaya Nakamura ◽  
Ryuta Sato ◽  
Keiichi Shirase
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Chip Thickness ◽  
Previous Method ◽  
Cutting Edge ◽  
Force Model ◽  
End Mill ◽  
Uncut Chip Thickness ◽  
Ball End Mill ◽  
Tool Rotation

A new method, which accurately predicts cutting force in ball end milling considering cutting edge around center web, has been proposed. The new method accurately calculates the uncut chip thickness, which is required to estimate the cutting force by the instantaneous rigid force model. In the instantaneous rigid force model, the uncut chip thickness is generally calculated on the cutting edge in each minute disk element piled up along the tool axis. However, the orientation of tool cutting edge of ball end mill is different from that of square end mill. Therefore, for the ball end mill, the uncut chip thickness cannot be calculated accurately in the minute disk element, especially around the center web. Then, this study proposes a method to calculate the uncut chip thickness along the vector connecting the center of the ball and the cutting edge. The proposed method can reduce the estimation error of the uncut chip thickness especially around the center web compared with the previous method. Our study also realizes to calculate the uncut chip thickness discretely by using voxel model and detecting the removal voxels in each minute tool rotation angle, in which the relative relationship between a cutting edge and a workpiece, which changes dynamically during tool rotation. A cutting experiment with the ball end mill was conducted in order to validate the proposed method. The results showed that the error between the measured and predicted cutting forces can be reduced by the proposed method compared with the previous method.

Research on Feedrate Optimization Based on Cutting Force Model with Double Effect for the Ball-End Milling

2011 ◽  
Vol 291-294 ◽  
pp. 2965-2969
Author(s):  
Yu Jun Cai ◽  
Hua Shen ◽  
Tie Li Qi
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Double Effect ◽  
Machining Process ◽  
Force Model ◽  
Optimization Strategy ◽  
Cutting Force Model ◽  
Ball End Mill ◽  
Ball End Milling ◽  
Feedrate Optimization

A new cutting force model of ball-end mill with double effect is developed through analysing the machining process by using differential geometry. The cutting force model is needed to be revised for the component force in Z direction because of the offset to the actual results. The cutting force and the ball-end milling force coefficients can be given with numerical method. A feedrate optimization strategy is also proposed based on the developed cutting force model and tested effectively.

Experimental Design Methodology in Ball End Milling of C45 Material by Using Tool Tilt Angle - Analysis and Estimation of Surface Roughness Variation

2013 ◽  
Vol 371 ◽  
pp. 48-53 ◽  
Author(s):  
Ioan Pasca ◽  
Mircea Lobonțiu ◽  
Róbert Čep ◽  
Mihai Banica
Keyword(s):  
Surface Roughness ◽  
Tilt Angle ◽  
End Milling ◽  
Milling Process ◽  
Experimental Methodology ◽  
Ball End Mill ◽  
Ball End Milling ◽  
Qualitative And Quantitative ◽  
Tool Tilt Angle ◽  
Experimental Design Methodology

Due to the expansion of milling process with ball end mill in various branches of industry it became necessary for this process to be optimized. For this purpose it is necessary to identify the parameters that influence the process and establish their value for witch the results obtained to be the maximum in terms of qualitative and quantitative. Roughness of the surface machined can be considered as an important element that reflects the degree of successful optimization of this process. In order to solve the problems relating to the analysis and estimation of the surface roughness variation in ball end milling of C45 material with tool tilt angle, in this paper it was designed an experimental methodology followed by analysis of experimental data and estimation of surface roughness variation. The experimental research methodology presented in this paper can be extrapolated and used in a large number of processes.

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