A Study on Trial-Less Machining Using Virtual Machining Simulator for Ball End Mill Operation(Analytical advancement of machining process)

2005 ◽  
Vol 2005.3 (0) ◽  
pp. 1115-1120 ◽  
Author(s):  
H. Narita ◽  
S. Kato ◽  
L. Y. Chen ◽  
H. Fujimoto ◽  
K. Shirase ◽  
...  
Keyword(s):  
Machining Process ◽  
End Mill ◽  
Ball End Mill ◽  
Virtual Machining ◽  
Mill Operation

A Method for Using a Virtual Machining Simulation to Consider Both Equivalent CO2Emissions and Machining Costs in Determining Cutting Conditions

2015 ◽  
Vol 9 (2) ◽  
pp. 115-121 ◽  
Author(s):  
Hirohisa Narita ◽  
Keyword(s):  
Evaluation System ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Machining Process ◽  
Machining Simulation ◽  
End Mill ◽  
Virtual Machining ◽  
Mill Operation ◽  
Nc Program

An evaluation system for calculating equivalent CO2emissions and machining costs is developed using an activity-based model. The system can evaluate a machining process from an NC program, workpiece information, and cutting tool information, and it can then calculate accurate equivalent CO2emissions and the machining cost. The cutting speed of an end mill operation is evaluated in terms of the equivalent CO2emission and the machining cost. Based on the results, optimal cutting conditions are determined to minimize the equivalent CO2emissions and the machining cost to the extent possible.

scholarly journals Trial-Less Machining Using Virtual Machining Simulator for Ball End Mill Operation

2006 ◽  
Vol 49 (1) ◽  
pp. 50-55 ◽  
Author(s):  
Hirohisa NARITA ◽  
Lian-yi CHEN ◽  
Hideo FUJIMOTO ◽  
Keiichi SHIRASE ◽  
Eiji ARAI
Keyword(s):  
End Mill ◽  
Ball End Mill ◽  
Virtual Machining ◽  
Mill Operation

scholarly journals Influence of Cutting Parameters to Surface Area Roughness in Dimple Machining Using Milling Process

2021 ◽  
Vol 18 (3) ◽  
Author(s):  
M.A. Hanafiah ◽  
A.A. Aziz ◽  
A.R. Yusoff
Keyword(s):  
Surface Area ◽  
Feed Rate ◽  
Research Work ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
End Mill ◽  
Ball End Mill

Surface quality is among the predominant criterion in measuring machining process performance, including milling. It is extremely dependent on the process variable, such as cutting parameters and cutting tool conditions. The main intention of this research work is to study the effect of the milling machining parameters, including depth of cut, spindle speed, feed rate as well as machining pattern to the final surface area roughness of the fabricated dimple structure. The concave profile of the dimple is machined at the right angle to a flat Al6061 specimen using a ball end mill attached to a 3-axis CNC milling machine, and the surface area of the concave profile is measured using 3D measuring laser microscope. It is observed that surface area roughness reacts with the spindle speed and feed rate with different tool sizes. Based on the result gained, the work has successfully characterised the influence of studied milling parameters on the dimple surface area roughness, where within the range of the studied parameter, the surface area roughness varies only less than 2.2 μm. The research work will be continued further on the incline milling technique and micro size ball end mill.

Modeling of Cutting Process with Cutter Axis Inclination

2011 ◽  
Vol 223 ◽  
pp. 66-74 ◽  
Author(s):  
Takashi Matsumura
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Cutting Temperature ◽  
Cutting Process ◽  
Mechanistic Models ◽  
End Mill ◽  
High Quality ◽  
Ball End Mill ◽  
Milling Operations ◽  
Edge Roughness

Multi-axis controlled machining has been increasing with the demand for high quality in mold manufacturing. The cutter axis inclination should be properly determined in the milling operations. The paper discusses the cutting process of ball end mill with the cutter axis inclination. Two mechanistic models are presented to show the effect of the cutter axis inclination on the tool wear and the surface finish. The actual cutting time during a rotation of the cutter reduces with increasing the cutter axis inclination. Then, the tool is cooled in the non-cutting time. The tool wear is suppressed with reducing the cutting temperature. The surface finish is also improved by increasing cutting velocities with the cutter axis inclination. When the cutter is inclined in the feed direction, the effect of the edge roughness on the surface finish is eliminated. The discussion based on the simulation is verified in the cutting tests for brittle materials.

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

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.

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.

On the Flexible Abrasive Tool for Nanofinishing of Complex Surfaces

2019 ◽  
Vol 18 (01) ◽  
pp. 157-166 ◽  
Author(s):  
Mithun Sarkar ◽  
V. K. Jain ◽  
Ajay Sidpara
Keyword(s):  
Surface Roughness ◽  
Corrosion Inhibitor ◽  
Abrasive Tool ◽  
End Mill ◽  
Complex Surfaces ◽  
Ball End Mill ◽  
Workpiece Surface ◽  
Abrasive Particles ◽  
Processing Step ◽  
Finishing Tool

Nanofinishing of complex surfaces is an important but costly processing step for many products for performing their functions satisfactorily. This paper deals with the development of a flexible abrasive tool for nanofinishing of complex surfaces. A flexible finishing tool similar to the ball end mill is developed by curing Polydimethylsiloxane (PDMS). A bowl-shaped copper workpiece is finished to nanometer surface roughness value. Different sizes of abrasive particles are used to reduce surface roughness value of the workpiece. A corrosion inhibitor is mixed with the abrasive slurry to protect the finished copper workpiece surface. A final surface roughness value of 50[Formula: see text]nm has been achieved with a variation up to 70[Formula: see text]nm on different locations of the bowl-shaped workpiece.

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