scholarly journals Evaluation of Geometric Deviations Inherent to 5 Axis Machining Center Based on Checkered Pattern of Machined Surface Using Ball End Milling

2012 ◽  
Vol 78 (786) ◽  
pp. 659-668
Author(s):  
Akinori SAITO ◽  
Kazuyoshi KONDO
Keyword(s):  
End Milling ◽  
Machined Surface ◽  
Ball End Milling ◽  
Machining Center ◽  
Geometric Deviations ◽  
Checkered Pattern

Gloss Estimating Method of Finished Surface Machined by Ball Nose End-Milling under Constant Contact Angle with a Five-Axis Controlled Machining Center

2012 ◽  
Vol 516 ◽  
pp. 475-480
Author(s):  
Kenichi Terada ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
Keiji Ogawa
Keyword(s):  
Feed Rate ◽  
End Milling ◽  
Work Piece ◽  
Machined Surface ◽  
Ball End Milling ◽  
Machining Center ◽  
Reflected Light ◽  
Finished Surface ◽  
Constant Contact Angle ◽  
Five Axis

In recent years, studies have been conducted about creating metal moulds using a five-axis controlled machining centre with ball end milling. Most of these reports concern the programming of CAM based on geometry. However, there have been few reports related to polish-less finished surface. Furthermore, a specular surface like a mirror and finishing under a constant angle between ball end milling and the work piece have not been investigated. Therefore, this paper deals with the gloss of the machined surface when feed rate and pick-feed rate are changed to maintain constant surface roughness considering tool run-out under the condition that the angle between the tool and work piece in contact are inclined at 15. However, by changing the combination of feed rate and pick-feed rate, various specular changes and direction of disposition of reflected light were obtained. Therefore, we suggest a new method of evaluating the gloss of these finished surfaces. Comparing results by the proposed method with ones by a glossmeter, it is clear that an appropriate ratio of feed rate and pick-feed rate is important for obtaining finished surface. Moreover, it is demonstrated that the proposed method is effective for estimating the gloss of the machined surface.

Surface Integrity Studies in Ball End Milling of Thin Shaped Cantilever Inconel 718

2014 ◽  
Author(s):  
Nandkumar N. Bhopale ◽  
Raju S. Pawade
Keyword(s):  
Surface Integrity ◽  
Inconel 718 ◽  
Tool Path ◽  
Surface Defects ◽  
End Milling ◽  
Surface Region ◽  
Lower Surface ◽  
Machined Surface ◽  
Ball End Milling ◽  
Integrity Analysis

The paper presents the surface integrity analysis in ball end milling of thin shaped cantilever plate of Inconel 718. It is noticed that the workpiece deflection has significantly contributed to machined surface integrity in terms of surface topography and subsurface microhardness. The ball end milling performed with 15° workpiece inclination with horizontal tool path produced higher surface integrity which varies with the location of machined surface region. In general, the mid portion of the machined plate shows lower surface roughness and microhardness with less surface defects.

scholarly journals Experimental Verification of Chatter-Free Ball End Milling Strategy

2013 ◽  
Vol 7 (1) ◽  
pp. 45-51 ◽  
Author(s):  
Lin Lu ◽  
◽  
Masahiko Sato ◽  
Hisataka Tanaka ◽  
Keyword(s):  
Cutting Tool ◽  
End Milling ◽  
Cutting Parameters ◽  
Cutting Condition ◽  
Chatter Stability ◽  
Chatter Vibration ◽  
Ball End Milling ◽  
Machining Center ◽  
Avoidance Control ◽  
Avoidance Strategy

Chatter vibration frequently occurs in ball end milling. If the characteristics of the cutting tool system and cutting process are known, chatter stability in ball end milling can be evaluated. Hence, in this paper, a chatter-avoidance strategy based on a regenerative chatter theory is proposed to prevent the occurrence of chatter. This consists of a simulation of chatter stability and cutting condition control. When the characteristics of a vibration system change, this chatter-avoidance strategy cannot cope with it. Therefore, another chatter-avoidance control algorism that changes cutting parameters on a machining center is proposed. This can adapt to the change in the characteristics of the vibration systemduring cutting. The effectiveness of the two chatter-avoidance methods proposed is examined through experiments.

Sensitivity Analysis of Error Motions and Geometric Errors in the Case of Sphere-Shaped Workpiece

2020 ◽  
Author(s):  
Zongze Li ◽  
Ryuta Sato ◽  
Keiichi Shirase
Keyword(s):  
Sensitivity Analysis ◽  
Machine Tools ◽  
End Milling ◽  
Geometric Errors ◽  
Machined Surface ◽  
Error Sources ◽  
Motion Error ◽  
Machining Center ◽  
Machining Errors ◽  
Five Axis

Abstract Motion error of machine tool feed axes influences the machined workpiece accuracy. However, the influences of each error sources are not identical; some errors do not influence the machined surface although some error have significant influences. In addition, five-axis machine tools have more error source than conventional three-axis machine tools, and it is very tough to predict the geometric errors of the machined surface. This study proposes a method to analyze the relationships between the each error sources and the error of the machined surface. In this study, a kind of sphere-shaped workpiece is taken as a sample to explain how the sensitivity analysis makes sense in ball-end milling. The results show that the method can be applied for the axial errors, such as motion reversal errors, to make it clearer to obverse the extent of each errors. In addition, the results also show that the presented sensitivity analysis is useful to investigate that how the geometric errors influence the sphere surface accuracy. It can be proved that the presented method can help the five-axis machining center users to predict the machining errors on the designed surface of each axes error motions.

A New Algorithm for the Numerical Simulation of Machined Surface Topography in Multiaxis Ball-End Milling

2008 ◽  
Vol 130 (1) ◽  
Author(s):  
Wei-Hong Zhang ◽  
Gang Tan ◽  
Min Wan ◽  
Tong Gao ◽  
David Hicham Bassir
Keyword(s):  
Numerical Simulation ◽  
Surface Topography ◽  
End Milling ◽  
Computing Time ◽  
Cutting Edge ◽  
Machining Parameters ◽  
Step Method ◽  
Time Step ◽  
Machined Surface ◽  
Ball End Milling

In milling process, surface topography is a significant factor that affects directly the surface integrity and constitutes a supplement to the form error associated with the workpiece deformation. Based on the tool machining paths and the trajectory equation of the cutting edge relative to the workpiece, a new and general iterative algorithm is developed here for the numerical simulation of the machined surface topography in multiaxis ball-end milling. The influences of machining parameters such as the milling modes, cutter runout, cutter inclination direction, and inclination angle upon the topography and surface roughness values are studied in detail. Compared with existing methods, the basic advantages and novelties of the proposed method can be resumed below. First, it is unnecessary to discretize the cutting edge and tool feed motion and rotation motion. Second, influences of cutting modes and cutter inclinations are studied systematically and explicitly for the first time. The generality of the algorithm makes it possible to calculate the pointwise topography value on any sculptured surface of the workpiece. Besides, the proposed method is proved to be more efficient in saving computing time than the time step method that is commonly used. Finally, some examples are presented and simulation results are compared with experimental ones.

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