scholarly journals Study on the Design and Cutting Performance of a Revolving Cycloid Milling Cutter

2019 ◽  
Vol 9 (14) ◽  
pp. 2915 ◽  
Author(s):  
Guangyue Wang ◽  
Xianli Liu ◽  
Weijie Gao ◽  
Bingxin Yan ◽  
Tao Chen
Keyword(s):  
Titanium Alloy ◽  
End Milling ◽  
Tangential Force ◽  
Boundary Curve ◽  
Cutting Performance ◽  
Machining Process ◽  
Rake Face ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Five Axis

Problems such as low machining efficiency, severe tool wear and difficulty in safeguarding surface quality always exist in the machining process of titanium alloy with ball-end milling cutters. To address these issues, the design and manufacture of a revolving cycloid milling cutter for titanium alloy processing were studied in this paper. Firstly, the mathematical model of the revolving cycloid milling cutter contour surface was established. The parametric equation of an orthogonal helix cutting edge curve of a revolving cycloid milling cutter is presented. Then, the bottom boundary curve of the rake face is introduced. The five-axis grinding trajectory equation of revolving cycloid milling cutter rake face was derived based on the edge curve equation and coordinate transformation. Next, fabricating the revolving cycloid milling cutter and detecting the grinding accuracy of tool profile and geometric angle were performed. At last, a contrast test regarding the performance of the revolving cycloid milling cutter and the ball-end milling cutter in cutting titanium alloy TC11 was carried out. According to the test results, in comparison to the ball-end milling cutter, the revolving cycloid milling cutter had a smaller ratio of the axial force to the tangential force. Moreover, its flank face wore more slowly and evenly. As a result, a good surface processing quality can be maintained even under larger wear conditions, demonstrating an outstanding cutting performance.

Accurate preparation of mesoscopic geometric characteristics of ball end milling cutter and optimization of cutting performance

2021 ◽  
pp. 095440542110285
Author(s):  
Shucai Yang ◽  
Pei Han ◽  
Xiao Liu ◽  
Xin Tong
Keyword(s):  
Titanium Alloy ◽  
Laser Processing ◽  
End Milling ◽  
Cutting Temperature ◽  
Processing Parameters ◽  
Cutting Performance ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Edge Radius ◽  
Blunt Edge

According to the difficult machinability of titanium alloy, the research shows that the surface micro-textured technology can reduce the friction force and cutting temperature in the cutter-workpiece contact area. Starting with the precise preparation of micro textures by laser processing technology, this paper takes ball-end milling cutter milling titanium alloy as the research object, studies the influence of laser processing parameters on micro-textured size parameters, and optimizes the laser processing parameters as follows: laser power P = 40 W, scanning speed V = 1700 mm/s, scanning times N = 7 times, and spot diameter D = 40 μm. The distribution of temperature field and stress field during laser processing is analyzed, and the accuracy of the influence rule of laser processing parameters on micro-textured size parameters is verified, thus realizing the purpose of accurately preparing micro textures. The interactive influence of mesoscopic geometric features on the cutting performance of ball-end milling cutter is analyzed, and the genetic algorithm is used to optimize the parameters. The results show that the main factor affecting the force-heat characteristics of the tool is the blunt edge radius, and the interaction between the blunt radius of the cutting edge and the distance from blade is obvious. The optimized mesoscopic geometric parameters are as follows: the blunt edge radius is 20 μm, and the distance from blade is 110 μm, the micro-textured diameter is 30 μm, and the micro-textured spacing is 175 μm. The research content of this paper lays a foundation for efficient cutting of titanium alloy materials.

scholarly journals An Experimental Study on Milling Titanium Alloy with a Revolving Cycloid Milling Cutter

2020 ◽  
Vol 10 (4) ◽  
pp. 1423
Author(s):  
Guangyue Wang ◽  
Xianli Liu ◽  
Tao Chen ◽  
Weijie Gao
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Surface Quality ◽  
Axial Force ◽  
End Milling ◽  
Tangential Force ◽  
Helix Angle ◽  
Rake Angle ◽  
Milling Cutter ◽  
Ball End Milling

In this paper, a revolving cycloid milling cutter was designed with a larger effective cutting helix angle and rake angle than a ball end milling cutter of the same diameter. This new type of milling cutter can solve the problems of low machining efficiency, severe tool wear, and low surface quality in titanium alloy processing. A comparison of the cutting performance of titanium alloys processed by the revolving cycloid milling cutter and the ball end milling cutter was carried out to obtain the variation laws of the cutting force and the processing surface quality under different tool wear conditions. The result shows that the wear zone of the revolving cycloid milling cutter is shallow and wide compared to that of the ball end milling cutter. As the wear speeds up, the spoon-shaped wear gathering zone found in the ball end milling cutter does not happen with the revolving cycloid milling cutter. The revolving cycloid milling cutter can significantly lower the axial force, the tangential force, and the ratio of the axial force to the tangential force with a stable cutting process.

Research on micro-texture placement position and cutting performance of negative chamfering ball-end milling cutter

2021 ◽  
Vol 580 (1) ◽  
pp. 251-267
Author(s):  
Yang Shucai ◽  
Zhang Naishi ◽  
Su Shuai ◽  
Sun Jiankun ◽  
Wang Tianjiao
Keyword(s):  
End Milling ◽  
Cutting Performance ◽  
Milling Cutter ◽  
Ball End Milling

scholarly journals Models of the relationship among geometric parameters and anti-friction mechanism of micro-texture ball-end milling cutter

2018 ◽  
Vol 10 (6) ◽  
pp. 168781401878147 ◽  
Author(s):  
Xianli Liu ◽  
Xin Tong ◽  
Shucai Yang ◽  
Chunsheng He ◽  
Xiao Liu
Keyword(s):  
Titanium Alloy ◽  
End Milling ◽  
Geometric Parameters ◽  
Friction Mechanism ◽  
Milling Cutter ◽  
Characteristic Model ◽  
Ball End Milling ◽  
Texture Parameters ◽  
Efficient Processing ◽  
The Relationship

Researches on the effect of the micro-texture on the cutting performance and the life of cutters are mostly aimed at turning cutters, but there are few researches on the ball-end milling cutter. On the basis geometry of the micro-texture, the distribution and the relationship among the geometric parameters of micro-pits are studied. A mechanical characteristic model of machining titanium alloy with the micro-texture ball-end milling cutter is established. Optimal parameters of the micro-texture are determined by the simulation. By the test of machining the titanium alloy with the micro-texture ball-end milling cutter, anti-friction properties, the influence laws of the micro-texture diameter on forces, and area occupancy on the tool wear are studied. This article provides a theoretical reference for determining the location of the micro-texture on ball-end milling cutter and selecting texture parameters reasonably. The anti-friction mechanism of the micro-texture is revealed by the theory, which provides a theoretical basis for the efficient processing of titanium alloy.

Investigation on the stress field of milling titanium alloys with micro-textured ball-end milling cutter

2019 ◽  
Vol 233 (11) ◽  
pp. 2160-2172 ◽  
Author(s):  
Shucai Yang ◽  
Chunsheng He ◽  
Minli Zheng
Keyword(s):  
Titanium Alloy ◽  
Stress Field ◽  
Density Function ◽  
End Milling ◽  
Equivalent Stress ◽  
Force Density ◽  
Stress And Strain ◽  
Milling Force ◽  
Milling Cutter ◽  
Ball End Milling

In the milling of titanium alloy, the distribution of milling force and its related law of change seriously affect the physical properties of workpiece materials, the stress distribution on a cutter’s rake face and the interaction between the workpiece, the cutter and the chip. This article reports on a study of the stress field distribution under the conditions of anti-friction and anti-wear when cutting titanium alloy with a micro-textured ball-end milling cutter. Milling test data were used to establish empirical models of milling force and the contact area between the cutter and the chip. Based on this, the force density function of the cutter coordinate system was obtained and the equivalent stress and displacement of the cutter were simulated and analyzed. This in turn provided the means to acquire the instantaneous stress and strain relating to the cutter at any time. Analysis of the simulation results shows that the position in which the stress and strain are concentrated on the cutter is consistent with actual processing. This confirms the accuracy of the force density function and provides the basis for further study of thermo-mechanical coupling behaviors when engaged in using micro-textured ball-end milling cutters for the cutting of titanium.

scholarly journals Study on mechanical properties of titanium alloy with micro-texture ball-end milling cutter under different cutting edges

2020 ◽  
Vol 12 (7) ◽  
pp. 168781402090842
Author(s):  
Shucai Yang ◽  
Shuai Su ◽  
Xianliang Wang ◽  
Wei Ren
Keyword(s):  
Titanium Alloy ◽  
End Milling ◽  
Cutting Edge ◽  
Milling Force ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Edge Geometry ◽  
Optimum Parameters ◽  
Cutting Surface ◽  
Texture Parameters

When precision cutting titanium alloy, the cutting part of cutting tool is mainly concentrated in the cutting edge area, so there is a strong emphasis upon the cutting edge’s geometric parameters. Studies have found that putting a micro-texture on the cutting surface can reduce the cutting force. This article looks at the milling force involved in cutting titanium alloy with a micro-textured ball-end milling cutter with different shaped cutting edges. First, a milling model relating to different cutting edges is established based on the traditional model of milling force. Then, the effects of different cutting edge geometry parameters and micro-texture parameters on milling force are simulated and tested using a finite element method. With milling force serving as the evaluation index, the optimum micro-texture parameters for a blunt circular cutting edge are a micro-pit diameter of 40 μm, a distance between micro-pits of 175 μm, a distance from the cutting edge of 110 μm, and a blunt circle radius of 60 μm. For a negative chamfer edge, the optimum parameters were a micro-pit diameter of 50 μm, a distance between micro-pits of 175 μm, a distance from the cutting edge of 120 μm, an edge width of 200 μm, and an edge angle of 10°.

Thermo-mechanical coupling behaviour when milling titanium alloy with micro-textured ball-end cutters

2020 ◽  
Vol 234 (6) ◽  
pp. 562-575
Author(s):  
Minli Zheng ◽  
Chunsheng He ◽  
Shucai Yang
Keyword(s):  
Titanium Alloy ◽  
High Speed ◽  
Simulation Analysis ◽  
End Milling ◽  
Coupling Effect ◽  
Theoretical Calculations ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Mechanical Coupling ◽  
Coupling Behavior

The high-speed milling of titanium alloy is a very complex nonlinear dynamic cutting process, and there are mutual coupling effects between multiple physical fields of the tool. Therefore, the thermo-mechanical coupling behavior of micro-textured ball-end milling cutters during the cutting of titanium alloy was studied in depth, combined with theoretical calculations, milling experiments and simulation analysis. First, based on the experimental data of milling titanium alloy, the stress field of the micro-textured ball-end milling cutter was solved. Then, the dimensional method was used to solve the temperature field of the micro-textured ball-end milling cutter. Finally, the thermo-mechanical coupling simulation analysis of the micro-textured ball-end milling cutter was carried out, and the stress concentration area and tool breakage area of the micro-textured ball-end milling cutter under the thermo-mechanical coupling effect are obtained. This in turn gives a theoretical basis for further improving the performance and tool life of micro-textured cutters.

Modeling and Computer Simulation of Grinding for Ball-End Milling Cutter with Equal Normal Rake Angle

2008 ◽  
Vol 53-54 ◽  
pp. 225-230 ◽  
Author(s):  
Feng Jun Chen ◽  
Shao Hui Yin ◽  
S.J. Hu
Keyword(s):  
Simulation Analysis ◽  
End Milling ◽  
Rake Angle ◽  
Grinding Wheel ◽  
Rake Face ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Grinding Method ◽  
Different Shapes ◽  
Machining Characteristics

In this paper, a new mathematical model and grinding method of ball-end milling cutter are proposed, based on the orthogonal spiral cutting edge curve. The movements of grinding wheel and ball-end milling cutter are presented while grinding rake face. In order to grind conveniently and avoid interference, a conical wheel is also designed and employed to grind the rake face of ball-end milling cutter on a grinder. In order to improve the machining characteristics of ball-end milling cutter, the model of rake face with equal rake angle is established. The software of ball-end milling cutter is developed to design and optimize different shapes of rake face. Furthermore, the simulation analysis on rake face with equal rake angle is carried out to confirm the validation of the mathematical models.

scholarly journals Study on Milling Temperature of Titanium Alloy with Micro-Textured Ball End Milling Cutter under Radius of Blunt Edge

2020 ◽  
Vol 10 (2) ◽  
pp. 587
Author(s):  
Shucai Yang ◽  
Shuai Su ◽  
Xianli Liu ◽  
Pei Han
Keyword(s):  
Titanium Alloy ◽  
End Milling ◽  
Cutting Temperature ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Optimum Parameters ◽  
Cutting Heat ◽  
Milling Temperature ◽  
Combined Action ◽  
Blunt Edge

A high temperature is produced in the process of precision milling of titanium alloy, and the cutting temperature can be effectively reduced by placing a micro-texture on the tool surface. In order to study the milling temperature of micro-textured ball-end milling cutter in milling titanium alloy under the combined action of a blunt radius with different edges and a micro-texture with different parameters, a new method based on micro-element theory and the generation and transmission of cutting heat has been established. At the same time, the influence of different radii of blunt edges on the milling temperature is simulated by the finite element method and experimentally verified to explore the influence of different radii of a blunt edge and micro-texture parameters on the milling temperature. Taking the milling temperature as the evaluation index, the optimum parameters of micro-circular pit texture are as follows: the diameter of micro-circular pit is 40 micron, pit spacing is 225 micron, distance from cutting edge is 100 microns, and radius of the blunt edge is 60 microns.

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