scholarly journals Modelling and analysis of surface topography generated in end milling process

2021 ◽  
Author(s):  
ruihu zhou ◽  
Chen Qilin
Keyword(s):  
Surface Topography ◽  
End Milling ◽  
Complex Surface ◽  
Cutting Parameters ◽  
Milling Process ◽  
Surface Geometry ◽  
Experimental Conditions ◽  
Workpiece Surface ◽  
Proposed Model ◽  
Set Up

Abstract The surface topography of workpiece plays an important role in the performance and service life of workpiece. Complex surface parts are widely used in shipbuilding, aerospace and other industries. At present, the study of milling surface topography is mainly on 3-axis milling. A prediction model of milling surface topography is proposed, which can obtain the machined workpiece surface topography and roughness directly from cutting parameters, cutter location file and workpiece surface geometry. The effects of cutting parameters on surface roughness is discussed. Different milling experimental conditions are set up to validate the proposed model. This method can be used to analyze the surface topography of milling, and further to optimize the cutting parameters to improve the surface quality.

Study on the Machined Surface Geometry Generated by Multi-Axis Ball End Milling Process

2013 ◽  
Vol 770 ◽  
pp. 370-375
Author(s):  
Xiao Xiao Chen ◽  
Jun Zhao ◽  
Yong Wang Dong ◽  
Shuai Liu ◽  
Jia Bang Zhao
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Cutting Parameters ◽  
Peak Height ◽  
Milling Process ◽  
Depth Of Cut ◽  
Small Range ◽  
Surface Geometry ◽  
Machined Surface ◽  
Two Parameters

This paper investigated the surface generated by single factor experiment under multi-axis finish milling condition, and the effects of cutting parameters on surface textures, 2D and 3D surface topographies and surface roughness characteristics were analyzed. Surface features evaluation indicators of Ra, Rq, Rt, surface heights histogram, maximum valley depth and maximum peak height corresponding to various cutting parameters were presented and discussed. The machining marks are closely related with tool orientation angles. The orderly distributions of concave and convex patterns on the machined surface are produced by the special cutting orientation of the cutting edges. The feed per tooth, spindle speed, tilt angle, and lead angle apparently affect surface roughness, while depth of cut and radial width of cut have no obvious effects on the surface roughness when the two parameters values vary in a small range.

Mechanistic Modeling of the Ball End Milling Process for Multi-Axis Machining of Free-Form Surfaces

2000 ◽  
Vol 123 (3) ◽  
pp. 369-379 ◽  
Author(s):  
Rixin Zhu ◽  
Shiv G. Kapoor ◽  
Richard E. DeVor
Keyword(s):  
End Milling ◽  
Chip Thickness ◽  
Mechanistic Modeling ◽  
Free Form ◽  
Surface Geometry ◽  
Workpiece Surface ◽  
Ball End Milling ◽  
Modeling Approach ◽  
Free Form Surfaces ◽  
Cutting Point

A mechanistic modeling approach to predicting cutting forces is developed for multi-axis ball end milling of free-form surfaces. The workpiece surface is represented by discretized point vectors. The modeling approach employs the cutting edge profile in either analytical or measured form. The engaged cut geometry is determined by classification of the elemental cutting point positions with respect to the workpiece surface. The chip load model determines the undeformed chip thickness distribution along the cutting edges with consideration of various process faults. Given a 5-axis tool path in a cutter location file, shape driving profiles are generated and piecewise ruled surfaces are used to construct the tool swept envelope. The tool swept envelope is then used to update the workpiece surface geometry employing the Z-map method. A series of 3-axis and 5-axis surface machining tests on Ti6A14V were conducted to validate the model. The model shows good computational efficiency, and the force predictions are found in good agreement with the measured data.

Cutting Path and Feedrate Optimization for Complex Surface Machining Using Ball End Milling Process

1995 ◽  
Author(s):  
Ee Meng Lim ◽  
Chia-Hsiang Menq ◽  
David W. Yen
Keyword(s):  
End Milling ◽  
Control Point ◽  
Local Maximum ◽  
Complex Surface ◽  
Milling Process ◽  
Surface Generation ◽  
Generation Model ◽  
Nc Programming ◽  
Machining Planning ◽  
Cutting Path

Abstract A new machining strategy, called cutting-path/adaptive-feedrate strategy, is proposed to improve the productivity of sculptured-surface productions subjected to force and dimensional constraints. In this proposed strategy, a new machining-planning aid, called maximum feedrate map, is developed. In this map, the maximum allowable feedrates at each control point along all machining directions subjected to the specified constraints are determined using a surface generation model. These local maximum-feedrate boundaries indicate the acceptable range of feedrates that a part programmer can use in the NC programming. In addition, the maximum feedrate map also provides the part programmer an important aid in selecting the cutting directions. The proposed strategy was applied to the machining planning for turbine blade die productions. Both computer simulation and experimental study were performed.

Generalized Mechanistic Force System Model of Ball-End Milling for Sculpture Surface Machining

2001 ◽  
Author(s):  
Ismail Lazoglu
Keyword(s):  
End Milling ◽  
Mechanistic Model ◽  
Milling Process ◽  
Force System ◽  
Workpiece Surface ◽  
Surface Machining ◽  
Ball End Milling ◽  
End Milling Process ◽  
Validation Experiments ◽  
Good Agreement

Abstract In this paper, a new mechanistic model is developed for the prediction of cutting force system in ball-end milling process. The key feature of the model includes the ability to calculate the workpiece / cutter intersection domain automatically for a given cutter location (CL) file, cutter and workpiece geometries. Moreover, an analytical approach is used to determine the instantaneous chip load and cutting forces. The model also employs a Boolean approach for given cutter, workpiece geometries, and the CL file in order to determine the surface topography and scallop height variations along the workpiece surface which can be visualized in 3-D. Some of the typical results from the model validation experiments performed on Ti-6A1-4V are also reported in the paper. Comparisons of the predicted and measured forces as well as the surface topographies show good agreement.

Parametric Design of Ball-End Milling Tools for High Speed Milling

2014 ◽  
Vol 800-801 ◽  
pp. 484-488
Author(s):  
Cai Xu Yue ◽  
Fu Gang Yan ◽  
Lu Bin Li ◽  
Hai Yan You ◽  
Qing Jie Yu
Keyword(s):  
High Speed ◽  
Parametric Design ◽  
End Milling ◽  
Complex Surface ◽  
Cutting Parameters ◽  
Secondary Development ◽  
Design System ◽  
Work Piece ◽  
Milling Cutter ◽  
Ball End Milling

Ball-end milling cutter is widely used in machining complex surface parts , and it is need to select a reasonable geometric parameters of the milling cutter for different work piece materials and shapes and cutting parameters. This article is based on UG secondary development technology to develop the Multi-blade ball-end milling cutter parametric design system, it is automatic, fast and efficient to build all kinds of parameters of double, three and four blades ball-end milling cutter model required for user.

Research on the Cutting Characteristics of Coated Tools on End Milling Nickel-Based Superalloy Mar-M247

2013 ◽  
Vol 652-654 ◽  
pp. 2105-2108
Author(s):  
Xu Xing Jin
Keyword(s):  
Feed Rate ◽  
End Milling ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Workpiece Surface ◽  
Nickel Based Superalloy ◽  
Coated Tools ◽  
Set Up ◽  
Wear Tool ◽  
Tool Cutting

Mar-M247 is widely used in industry for its excellent mechanical properties at high temperatures, but it has the shortcoming of difficulty manufactured. In order to obtain the cutting characteristics of Mar-M247, firstly, an end milling experiment was set up accordingly, where three types of cutting tools coated respectively by TiN, TiCN and TiAlN were employed. Then the parameters of cutting speed and feed rate were defined as the tool cutting variables. Finally, based on different cutting variables, the performance of tool wear, tool life, and workpiece surface roughness were analyzed and discussed. The results indicate when the tool coated by TiAlN, cutting speed of range 1600 ~ 3200 rpm and feed rate of range 0.06 ~ 0.08 mm / tooth are chosen together, the integrated states manufactured of the tool and the workpiece would be best, the method of this research can provide some references for studying others Nickel-based superalloys.

Modeling and prediction of the average roughness of UNS S31600 in superfinishing turning

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Younes Ech-charqy ◽  
Rachid Radouani ◽  
Mohamed Essahli
Keyword(s):  
Cutting Parameters ◽  
Hybrid Modeling ◽  
Elementary Operation ◽  
Cutting Conditions ◽  
Average Roughness ◽  
Workpiece Surface ◽  
Content Type ◽  
The Real ◽  
Proposed Model ◽  
Real Behavior

PurposeThe purpose of this paper is to realize an effective hybrid modeling (empirical-geometric) in order to describe the real behavior of the average roughness variation of the workpiece surface in turning with an elementary operation of superfinishing, using different analytic methodologies. The previous works are limited to describe the roughness for the usual elementary operations, citing the roughing and the semi-finishing, while this analysis builds technical rails for the industrialists in order to well conduct the operation of superfinishing in turning, by choosing the cutting parameters from the proposed model.Design/methodology/approachA statistical analysis of the average roughness measurements capability study, by the statistical process control method SPC and the ANN artificial neuron network, Levenberg–Marquardt's methods modified Monte Carlo SRM response surface.FindingsThe objective of this work was to describe the average roughness generated by the penetration of the cutting tool into a part in superfinishing turning. First, the authors used artificial colony analysis to determine optimal cutting conditions in order to have an average roughness lower than 0.8 µm. The cutting conditions selected: (1) the feed rate f ϵ [0.05; 0.2] mm/rev; (2) the pass depth ap ϵ [0.25; 1] mm; (3) the corner radius re = 0.2 mm and (4) cutting speed Vc ϵ [75; 100] m/min.Originality/valueThis work consists to realize an effective hybrid modeling (empirical-geometric) in order to describe the real behavior of the average roughness variation of the workpiece surface in turning with an elementary operation of superfinishing, using different analytic methodologies. The previous works are limited to describe the roughness for the usual elementary operations, citing the roughing and the semi-finishing, while this analysis builds technical rails for the industrialists in order to well conduct the operation of superfinishing in turning, by choosing the cutting parameters from the proposed model.

Optimization of the Process Parameters in Milling of Aluminum Alloys

2020 ◽  
Vol 896 ◽  
pp. 293-298
Author(s):  
Nicolae Craciunoiu ◽  
Emil Nicusor Patru ◽  
Adrian Sorin Rosca ◽  
Dumitru Panduru ◽  
Marin Bica
Keyword(s):  
Aluminum Alloys ◽  
Tool Wear ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Milling Process ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Experimental Conditions ◽  
Milling Parameters

In order to control the temperature during milling process of aluminum alloys and keeping as minimum as possible, the choice of the cutting parameters and their optimization is very important, both for the tool wear but also for the surface quality of machined surface. The main purpose of this paper is to find the optimum values of the milling parameters (rotational speed and depth of cut) so that the minimum value for the temperature to be obtained. Using adequate experimental conditions with contact measurements techniques (thermocouple K-type) carried out on the some types of aluminum alloys and the appropriate statistical instruments, the most influencing cutting parameters and their values on the cutting temperature can be found. The results are presented both analytical and graphical.

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