A Tool Tilt Angle Calculation Method in 5-axis Flat-end Milling for Free Surface Machining

Aero-engine blades are manufactured by electroforming process with electrodes. The blade electrode is usually machined with five-axis micromilling to get required profile roughness. Tool path planning parameters, such as cutting step and tool tilt angle, have a significant effect on the profile roughness of the micro-fillet of blade electrode. In this paper, the scallop height model of blade electrode micro-fillet processed by ball-end milling cutter was proposed. Effects of cutting step and tool tilt angle the machined micro-fillet profile roughness were predicted with the proposed scallop height model. The cutting step and tool tilt angle were then optimised to ensure the contour precision of the micro-fillet shape requirement. Finally, the tool path planning was generated and the machining strategy was validated through milling experiments. It was also found that the profile roughness was deteriorated due to size effect when the cutting step decreased to a certain value.

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Effect of tool tilt angle on cutting characteristics in micro-ball end milling

The Proceedings of The Manufacturing & Machine Tool Conference ◽

10.1299/jsmemmt.2019.13.a35 ◽

2019 ◽

Vol 2019.13 (0) ◽

pp. A35

Author(s):

Kento YASUTOMI ◽

Katsuhiko SAKAI ◽

Hiroo SHIZUKA

Keyword(s):

Tilt Angle ◽

End Milling ◽

Ball End Milling ◽

Tool Tilt Angle

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

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.371.48 ◽

2013 ◽

Vol 371 ◽

pp. 48-53 ◽

Cited By ~ 3

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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Evaluation of Surface Roughness in Five-Axis Ball-End Milling

Proceedings of Higher Educational Institutions Маchine Building ◽

10.18698/0536-1044-2020-5-21-31 ◽

2020 ◽

pp. 21-31

Author(s):

B.B. Ponomarev ◽

S.H. Nguyen

Keyword(s):

Surface Roughness ◽

Tilt Angle ◽

End Milling ◽

Free Form ◽

Tool Orientation ◽

Ball End Milling ◽

Lead Angle ◽

Tool Tilt Angle ◽

Five Axis ◽

Free Form Surfaces

Unlike three-axis machining, five-axis machining allows the end tool or workpiece to be oriented at any angle relative to the machine axis OZ. It can be achieved by changing the values of the tool tilt angle and lead angle relative to the surface normal in the contact zone of the tool surface and the workpiece, taking into account the direction of the table feed. The article presents experimental results of analyzing the influences of tool orientation on transverse roughness during ball end milling using 2-flute and 4-flute 8 mm diameter mills. The analysis the arithmetic mean deviation of the assessed profile at various values of tool tilt angle and lead angle showed that the position of the tool point with a zero cutting speed significantly affects the surface quality. The results of the evaluation of the tool orientation influence on the surface roughness enable the selection of optimal tool orientation angles when developing control programs for end milling of free-form surfaces on five-axis CNC milling machines.

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