scholarly journals Design and Optimization of Variable Pitch End Mills Based on Dynamic Balance Accuracy

2021 ◽  
Author(s):  
Wanying Nie ◽  
Minli Zheng ◽  
Shicheng Xu ◽  
Yuexiu Liu ◽  
Haibin Yu
Keyword(s):  
High Speed ◽  
Dynamic Balance ◽  
Optimization Method ◽  
Relative Displacement ◽  
Milling Process ◽  
Structure Design ◽  
End Mill ◽  
Variable Pitch ◽  
Balance Accuracy ◽  
End Mills

Abstract Variable pitch end mills are widely used in the high-speed milling process due to having better vibration reduction properties. However, because of the unequal pitch angles and the asymmetrical structure of end mills, there are principle error, poor dynamic balance accuracy, and serious tool vibration problems in the milling process. In order to improve the dynamic balance accuracy of variable pitch end mills, the structure of the end mill is designed and optimized based on the minimum eccentricity criterion in this paper. Firstly, by analyzing the dynamic balance of variable pitch end mills, the relationship between it and eccentricity is defined, and the end section model and the centroid equation are developed through the structure design of end mills. Then, the optimization method of variable pitch end mills is analyzed, the eccentricity decreases from e0= 150um to e'0 = 3um based on this method. the structure of the end mill is optimized to meet the design criteria, which improves the balance accuracy level of end mills. Finally, through the modal analysis for the optimized structure of the variable pitch end mill, the maximum relative displacement in the mode is reduced by about 17%, it is verified that the optimized end mills have better dynamic performances, which is of great significance for alleviating the cutting vibration and improving the cutting stability.

Design and Application of High-Speed Variable Pitch End Mill Based on Milling Stability

2011 ◽  
Vol 314-316 ◽  
pp. 599-602
Author(s):  
Qing Hua Song ◽  
Xing Ai
Keyword(s):  
Machine Tool ◽  
Dynamic Stability ◽  
Design Variable ◽  
High Speed ◽  
Milling Process ◽  
End Mill ◽  
Structural Geometry ◽  
Variable Pitch ◽  
Milling Stability ◽  
End Mills

The strong demand for increasing productivity and workpiece quality in milling process makes the machine-tool system operate close to the limit of its dynamic stability. Milling cutters with variable pitch angles can be very effective in improving stability against chatter for certain speed ranges, which will be predicted by the model presented here. The present paper deals with the design of structural geometry of variable pitch end mills in detail. Based on the analysis of tooth engagement factor, which is expressed and extended in the paper, an approach is proposed to design variable pitch end mill with high milling stability. The certain speed ranges with high milling stability are given.

Monitoring of End-Mill Behavior with Its Projection Image

2006 ◽  
Vol 315-316 ◽  
pp. 474-480
Author(s):  
Dun Wen Zuo ◽  
Yoshihiro Kawano
Keyword(s):  
High Speed ◽  
Small Diameter ◽  
Milling Process ◽  
Measuring System ◽  
End Mill ◽  
Static State ◽  
High Speed Cutting ◽  
Projection Image ◽  
Image Width ◽  
End Mills

End mills with small diameter have found their wide application with the development of high-speed cutting. It becomes more and more important to develop effective methods to monitor and control the milling process with small end mills. In this paper, a measuring system of projection image for small end mills is introduced, and the application of the projection image to monitor the behavior of the end mill is discussed. It is found that for static state of the end mill, the measurement accuracy can be easily controlled within 1 μm. When the end mill rotates, it is not so difficult to control the accuracy within 3 μm. By using of the change in image width, the radial wear of end mill can be predicted. On the other hand, if the centre shift of the image is pre-measured, the deflection of the end mill during cutting can be predicted.

In-Process Tool Wear Detection of Uncoated Square End Mill Based on Electrical Contact Resistance

2016 ◽  
Vol 10 (5) ◽  
pp. 767-772 ◽  
Author(s):  
Amine Gouarir ◽  
◽  
Syuhei Kurokawa ◽  
Takao Sajima ◽  
Mitsuaki Murata ◽  
...  
Keyword(s):  
Tool Wear ◽  
Contact Resistance ◽  
High Speed ◽  
Detection System ◽  
Electrical Contact ◽  
Milling Process ◽  
End Mill ◽  
Electrical Contact Resistance ◽  
End Mills ◽  
Process Detection

This paper presents a method for in-process detection of tool wear in square end mills. The developed high-speed tool wear detection system uses the contact resistance between the tool and workpiece as a gauge to monitor the progression of tool wear. The electrical resistance decreases with an increase in contact area on the tool flank. In the experiments conducted in our previous study, the target was the face milling process. In the present study, the experiments were conducted on down cut milling with a square end mill. The results are presented based on the observations made on the relationship between the area of tool flank wear and tool-work contact resistance. In conclusion, the results of the experiment show that the present tool wear detection system is effective as an in-process tool wear detection system for square end mills.

Geometric Modeling of Cutter/Workpiece Engagements for Helical Milling With Flat End Mills

2007 ◽  
Author(s):  
Eyyup Aras ◽  
Derek Yip-Hoi
Keyword(s):  
Geometric Modeling ◽  
High Speed ◽  
Tool Path ◽  
Cutting Tool ◽  
Milling Process ◽  
Helical Milling ◽  
Mapping Technique ◽  
Depth Of Cut ◽  
Modeling Methodology ◽  
End Mills

Helical milling is a 3-axis machining operation where a cutting tool is feed along a helix. This operation is used in ramp-in and ramp-out moves when the cutting tool first engages the workpiece, for contouring and for hole machining. It is increasingly finding application as a means for roughing large amounts of material during high speed machining. Modeling the helical milling process requires cutter/workpiece engagements (CWEs) geometry in order to predict cutting forces. The calculation of these engagements is challenging due to the complicated and changing intersection geometry that occurs between the cutter and the in-process workpiece. In this paper we present a geometric modeling methodology for finding engagements during helical milling with flat end mills. A mapping technique has been developed that transforms a polyhedral model of the removal volume from Euclidean space to a parametric space defined by location along the tool path, engagement angle and the depth-of-cut. As a result, intersection operations are reduced to first order plane-plane intersections. This approach reduces the complexity of the cutter/workpiece intersections and also eliminates robustness problems found in standard polyhedral modeling and improves accuracy over the Z-buffer technique. The reported method has been implemented and tested using a combination of commercial applications. This paper highlights ongoing collaborative research into developing a Virtual Machining System.

The use of assembled cutting tool with damping elements to reduce mechanical vibrations

2021 ◽  
Author(s):  
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
End Mill ◽  
Mechanical Vibrations ◽  
Machined Surface ◽  
High Speed Cutting ◽  
End Mills ◽  
Cutting Modes

Aspects of vibration reduction during machining on metal-cutting machines to improve the quality of machined surfaces at moderate and high-speed cutting modes are considered. End mills with damping elements made of different materials, which provide the control of tool rigidity, are developed. Keywords: vibrations, end mill, vibrations, machined surface, damping. [email protected]

High Precise Milling Process by cBN End Mills

2012 ◽  
Vol 6 (4) ◽  
pp. 542-545 ◽  
Author(s):  
Katsumi Naganuma ◽  
◽  
Masato Mori
Keyword(s):  
Research And Development ◽  
Tool Life ◽  
Small Diameter ◽  
Milling Process ◽  
Machining Accuracy ◽  
End Mill ◽  
Hard Materials ◽  
Machining Quality ◽  
Machining Test ◽  
End Mills

Molding technology is one way of producing the micro-precision parts required by various industries. To Advance this molding technology, various elemental technologies related to materials, construction and machiningmethods are evolving together. One of these elemental technologies is milling by end mill. Further research and development of end mill is underway in response to improvement and requirement of molding technologies. There are various demands for end mills such as improvement of tool life and stable machining quality. Here we report the small diameter cBN end mill, developed as a tool to provide with stable machining accuracy with long tool life for high hard materials. We report the investigations and characteristics at the time of development and show the machining test.

Experimental Study on Ball End Mill in Glass Machining at High Speed

2011 ◽  
Vol 314-316 ◽  
pp. 1167-1170
Author(s):  
Zhi Wei ◽  
Ji Hong Jia ◽  
Mei Lin Gu ◽  
Chao Zuo ◽  
Xing Zhen Jin
Keyword(s):  
High Speed ◽  
Experimental System ◽  
Milling Process ◽  
End Mill ◽  
Ball End Mill ◽  
Milling Force ◽  
Milling Tool ◽  
Explicit Analysis ◽  
Stress And Deformation ◽  
The Relationship

This paper describes the experimental system of milling force, the tool geometrical feature and the certain experimental condition in the section of experimental case, which also makes an explanation about the designing of experimental case and the analysis of the experimental data. It also represents the relationship between coefficients associated with the milling process and the milling force applied on the tool in detail. A finite element method is used to make an explicit analysis on the stress and deformation of the milling tool under the application of certain milling force. Finally, a summary is made to conclude the study and its results.

Research on Dynamic Temperature Field Modeling of the Solid Carbide End Mill in High-Speed Milling

2015 ◽  
Vol 1089 ◽  
pp. 350-353
Author(s):  
Wei Bo ◽  
Guang Yu Tan ◽  
Lin Lin Guo ◽  
Guang Hui Li
Keyword(s):  
Temperature Field ◽  
Heat Source ◽  
High Speed ◽  
Cutting Temperature ◽  
Helical Coil ◽  
End Mill ◽  
Dynamic Temperature ◽  
Solid Carbide ◽  
End Mills ◽  
Coil Heat

Cutting temperature is a key factor in impacting the solid carbide end mill’s life, the rule of solid carbide end mill temperature field is the research focus. In this paper, the solid carbide end mill helical side edge is regarded as a helical coil heat source, the tool chip friction surface is considered as a surface heat source which consists of countless helical coil heat source. Based on heat source method, the model of continuous dynamic temperature field simulation of a solid carbide end mills cutting process is established.

Parametric Design of Tapered End Mills with Variable Pitch for Improving Stability

2014 ◽  
Vol 599-601 ◽  
pp. 381-384
Author(s):  
Li Lun He ◽  
Zhi Bing Liu ◽  
Xi Bin Wang ◽  
Wei Wei Lv
Keyword(s):  
Graphical Representation ◽  
Parametric Design ◽  
Design Method ◽  
Three Dimensional ◽  
Mathematical Expression ◽  
End Mill ◽  
Optimal Angle ◽  
Variable Pitch ◽  
End Mills ◽  
Design And Manufacture

For the problems about design and manufacture of the variable pitch tapered end mills, this study proposes a three-dimensional parametric design method of variable pitch mill. Firstly the equation of calculating the optimal angle between the pitch was presented .Considering existing different patches between two cutting edges, helix edge curve and cross-section groove model of tapered end mill were established .Secondly, mathematical expression of ball end teeth for tapered mill was derived, and all points data of tapered mill surface can be determined by established model. Through the graphical representation, the points set are translated into a solid model.

Dynamic Balance Analysis of Drum-Shape Rotor

2007 ◽  
Vol 10-12 ◽  
pp. 909-912
Author(s):  
H.B. Zhang ◽  
L. Zhou ◽  
Ying Xue Yao
Keyword(s):  
High Precision ◽  
High Speed ◽  
Dynamic Balance ◽  
Normal Direction ◽  
Rigid Rotor ◽  
Mass Imbalance ◽  
Geometrical Relation ◽  
Balance Accuracy ◽  
Balance Analysis ◽  
Gas Bearing

For rigid rotor that widely applied in gyroscopes, high precision dynamic balance is very important. The paper introduces a dynamic balance method for drum-shape gyroscope rotor: the rotor is supported by gas bearing; detecting the displacement of three points on the drum-shape rotor’s end-plane, obtaining its normal direction. Then according to geometrical relation of geometric axis and polar inertia axis, the dynamic trace of the rotor can be obtained, and the rotor’s mass imbalance is calculated. Experiment result shows that the method has high balance accuracy, particularly suit for high-speed gyroscope rotor whose mass imbalance is small.

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