Geometric Analysis of Machining Error with Tool Orientation in Ball End Milling

2017 ◽  
Vol 2017.9 (0) ◽  
pp. 101
Author(s):  
Hisanobu TERAI ◽  
Teruyuki ASAO ◽  
Koichi KIKKAWA ◽  
Yoshio MIZUGAKI
Keyword(s):  
End Milling ◽  
Geometric Analysis ◽  
Tool Orientation ◽  
Machining Error ◽  
Ball End Milling

scholarly journals A proposition for machining error estimation based on geometric analysis of ball end milling

2017 ◽  
Vol 83 (856) ◽  
pp. 17-00265-17-00265
Author(s):  
Hisanobu TERAI ◽  
Teruyuki ASAO ◽  
Koichi KIKKAWA ◽  
Yoshio MIZUGAKI
Keyword(s):  
Error Estimation ◽  
End Milling ◽  
Geometric Analysis ◽  
Machining Error ◽  
Ball End Milling

scholarly journals Study on Ball End Milling of Cylindrical Surface : Influence of Cutting Direction on Machining Error

2005 ◽  
Vol 2005.3 (0) ◽  
pp. 933-938 ◽  
Author(s):  
Lin LU ◽  
Hisataka TANAKA ◽  
Masahiko SATO ◽  
Bernard W. IKUA ◽  
Yoshihito MAEDA ◽  
...  
Keyword(s):  
Cylindrical Surface ◽  
End Milling ◽  
Machining Error ◽  
Ball End Milling ◽  
Cutting Direction

scholarly journals Effect of Tool Orientation on Surface Integrity During Ball End Milling of Titanium Alloy TC17

Procedia CIRP ◽  
2016 ◽  
Vol 56 ◽  
pp. 143-148 ◽  
Author(s):  
Pan Yang ◽  
Changfeng Yao ◽  
Shaohua Xie ◽  
Dinghua Zhang ◽  
Dou Xing Tang
Keyword(s):  
Titanium Alloy ◽  
Surface Integrity ◽  
End Milling ◽  
Tool Orientation ◽  
Ball End Milling

Tool Orientation Planning in Milling With Process Dynamic Constraints: A Minimax Optimization Approach

2018 ◽  
Vol 140 (11) ◽  
Author(s):  
Tao Huang ◽  
Xiao-Ming Zhang ◽  
Jürgen Leopold ◽  
Han Ding
Keyword(s):  
Tool Path ◽  
End Milling ◽  
Tool Path Generation ◽  
Optimization Approach ◽  
Path Generation ◽  
Tool Orientation ◽  
Minimax Optimization ◽  
Ball End Milling ◽  
Dynamic Constraints ◽  
Five Axis

In five-axis milling process, the tool path generated by a commercial software seldom takes the dynamics of the machining process into account. The neglect of process dynamics may lead to milling chatter, which causes overcut, quick tool wear, etc., and thus damages workpiece surface and shortens tool life. This motivates us to consider dynamic constraints in the tool path generation. Tool orientation variations in five-axis ball-end milling influence chatter stability and surface location error (SLE) due to the varying tool-workpiece immersion area and cutting force, which inversely provides us a feasible and flexible way to suppress chatter and SLE. However, tool orientations adjustment for suppression of chatter and SLE may cause drastic changes of the tool orientations and affects surface quality. The challenge is to strike a balance between the smooth tool orientations and suppression of chatter and SLE. To overcome the challenge, this paper presents a minimax optimization approach for planning tool orientations. The optimization objective is to obtain smooth tool orientations, by minimizing the maximum variation of the rotational angles between adjacent cutter locations, with constraints of chatter-free and SLE threshold. A dedicated designed ball-end milling experiment is conducted to validate the proposed approach. The work provides new insight into the tool path generation for ball-end milling of sculpture surface; also it would be helpful to decision-making for process parameters optimization in practical complex parts milling operations at shop floor.

Research about Elastic Mechanism of Error Generation in Ball End Milling based in Geometric Analysis

2011 ◽  
Author(s):  
Hisanobu Terai ◽  
Teruyuki Asao ◽  
Koichi Kikkawa ◽  
Yoshio Mizugaki
Keyword(s):  
End Milling ◽  
Geometric Analysis ◽  
Ball End Milling ◽  
Elastic Mechanism ◽  
Error Generation

Estimation of Machining Error in Ball-End Milling of Hemispherical Surface Based on Measured Cutting Force

2014 ◽  
Vol 1017 ◽  
pp. 692-695
Author(s):  
Kenji Shimana ◽  
Eiji Kondo ◽  
Shunichi Yamashita ◽  
Yoshihiro Kawano ◽  
Norio Kawagoishi
Keyword(s):  
Radial Direction ◽  
Normal Force ◽  
End Milling ◽  
End Mill ◽  
Machining Error ◽  
Ball End Milling ◽  
Machining Errors ◽  
Hemispherical Surface ◽  
The Moment ◽  
Cutting Point

For a cutting process using a low-rigidity end mill, it is very important to be able to estimate the degree of machining error caused by the deflection of the tool. The purpose of this study is to establish a method of estimating, in real time, the machining error caused by the deflection at the cutting point of an end mill. To this end, in this research, a method for estimating the machining error caused by the deflection of the tool used for the ball-end milling of a hemispherical surface was verified by comparing the estimated and measured deflections of the tool. As a result, it was found that the machining errors in ball-end milling could be estimated from the normal force at the moment when the radial direction of the peripheral cutting edge is normal to the feed direction of the tool.

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.

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