scholarly journals Research on Grinding of Micro Ball End Mill with Equal Normal Rake Angle and Equal Radial Relief Angle

2019 ◽  
Vol 55 (5) ◽  
pp. 196
Author(s):  
Zhiqiang LIANG
Keyword(s):  
Rake Angle ◽  
End Mill ◽  
Ball End Mill ◽  
Relief Angle

A Novel CNC Grinding Method for Relief Surface Based on a CAM System

2011 ◽  
Vol 295-297 ◽  
pp. 2521-2525 ◽  
Author(s):  
Xiao Feng Yue ◽  
Fei Tang ◽  
Shu Zhe Li ◽  
Zhan Hua You ◽  
Xiao Hao Wang
Keyword(s):  
Coordinate System ◽  
Numerical Control ◽  
Grinding Wheel ◽  
End Mill ◽  
Ball End Mill ◽  
Relief Surface ◽  
Cnc Grinding ◽  
Relief Angle ◽  
Five Axis ◽  
Mill Machining

A novel algorithm for the ball-end mill relief using a five-axis computer numerical control (CNC) grinding machine and the simulation of the ball-end mill based on a CAM system is presented in this paper. In this study, In order to obtain an accurate normal relief angle, which is one of the key factors affecting tool cutting performance, a tool coordinate system based on the required relief angle and the cutting edge was established. Then, by the proposed tool coordinate system, an algorithm to determine the position between the grinding wheel and the tool is proposed, and then the relevant formulations are deduced. The coordinates of grinding point when the step of relief surface is grinded are calculated.Using the input data of a ball-end mill geometry, wheels geometry, wheel setting and machine setting, the NC code for machining will be generated. Then the code will be used as input to simulate the ball-end mill machining in 3 Dimension before real machining. The algorithm of ball-end mill relief can be authenticated by the 3D simulation system.

Modeling of Cutting Process with Cutter Axis Inclination

2011 ◽  
Vol 223 ◽  
pp. 66-74 ◽  
Author(s):  
Takashi Matsumura
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Cutting Temperature ◽  
Cutting Process ◽  
Mechanistic Models ◽  
End Mill ◽  
High Quality ◽  
Ball End Mill ◽  
Milling Operations ◽  
Edge Roughness

Multi-axis controlled machining has been increasing with the demand for high quality in mold manufacturing. The cutter axis inclination should be properly determined in the milling operations. The paper discusses the cutting process of ball end mill with the cutter axis inclination. Two mechanistic models are presented to show the effect of the cutter axis inclination on the tool wear and the surface finish. The actual cutting time during a rotation of the cutter reduces with increasing the cutter axis inclination. Then, the tool is cooled in the non-cutting time. The tool wear is suppressed with reducing the cutting temperature. The surface finish is also improved by increasing cutting velocities with the cutter axis inclination. When the cutter is inclined in the feed direction, the effect of the edge roughness on the surface finish is eliminated. The discussion based on the simulation is verified in the cutting tests for brittle materials.

Tool Path Generation for Five-Axis Controlled Machining of Free-Form Surface Using Barrel Tool: Control of Contact Point on Cutting Edge

2020 ◽  
Author(s):  
Tomonobu Suzuki ◽  
Koichi Morishige
Keyword(s):  
Tool Path ◽  
Contact Point ◽  
Cutting Edge ◽  
Free Form ◽  
End Mill ◽  
Ball End Mill ◽  
Surface Machining ◽  
Free Form Surface ◽  
The Cost ◽  
Five Axis

Abstract This study aimed to improve the efficiency of free-form surface machining by using a five-axis controlled machine tool and a barrel tool. The barrel tool has cutting edges, with curvature smaller than the radius, increasing the pick feed width compared with a conventional ball end mill of the same tool radius. As a result, the machining efficiency can be improved; however, the cost of the barrel tool is high and difficult to reground. In this study, a method to obtain the cutting points that make the cusp height below the target value is proposed. Moreover, a method to improve the tool life by continuously and uniformly changing the contact point on the cutting edge is proposed. The usefulness of the developed method is confirmed through machining simulations.

The Milling Cutter Design and Simulation for Complex Cavity Machining

2014 ◽  
Vol 800-801 ◽  
pp. 465-469
Author(s):  
An Shan Zhang ◽  
Xian Li Liu ◽  
Shu Cai Yang ◽  
Qi Zhang
Keyword(s):  
End Milling ◽  
Cutting Speed ◽  
End Mill ◽  
Ball End Mill ◽  
Flat Bottom ◽  
Good Surface ◽  
Complex Cavity ◽  
Cutter Design ◽  
Bottom Width ◽  
Curvature Interference

Complex cavity generally is machined in 3 axis or 3+2 axis machine tools, it has large amount of metal to be removed. For complex cavity machining, the cutting speed of ball end mill`s head point is zero, which makes its end milling ability poor; Torus cutter `s flat bottom width is wide, which causes curvature interference and concave-uncut. So this article designs a new kind of cutter for complex cavity roughing and semi-finishing, which can improve ball end mill`s poor end milling ability and decrease flat-end width. The simulation results show that the new cutter`s feasibility of machining complex cavity is better, and it can obviously reduce the amount of owe cutting compared with the torus cutter; At the same time, the new cutter can improve machining efficiency by 32.4% compared with the ball end mill, and good surface can also be generated.

On the Flexible Abrasive Tool for Nanofinishing of Complex Surfaces

2019 ◽  
Vol 18 (01) ◽  
pp. 157-166 ◽  
Author(s):  
Mithun Sarkar ◽  
V. K. Jain ◽  
Ajay Sidpara
Keyword(s):  
Surface Roughness ◽  
Corrosion Inhibitor ◽  
Abrasive Tool ◽  
End Mill ◽  
Complex Surfaces ◽  
Ball End Mill ◽  
Workpiece Surface ◽  
Abrasive Particles ◽  
Processing Step ◽  
Finishing Tool

Nanofinishing of complex surfaces is an important but costly processing step for many products for performing their functions satisfactorily. This paper deals with the development of a flexible abrasive tool for nanofinishing of complex surfaces. A flexible finishing tool similar to the ball end mill is developed by curing Polydimethylsiloxane (PDMS). A bowl-shaped copper workpiece is finished to nanometer surface roughness value. Different sizes of abrasive particles are used to reduce surface roughness value of the workpiece. A corrosion inhibitor is mixed with the abrasive slurry to protect the finished copper workpiece surface. A final surface roughness value of 50[Formula: see text]nm has been achieved with a variation up to 70[Formula: see text]nm on different locations of the bowl-shaped workpiece.

Five-Axis CNC Tool Grinding: Part I—Rake Face Grinding

2011 ◽  
Author(s):  
Mahmoud M. Rababah ◽  
Zezhong C. Chen
Keyword(s):  
Rake Angle ◽  
Grinding Process ◽  
Rake Face ◽  
End Mill ◽  
Grinding Wheels ◽  
Robust Algorithm ◽  
Geometric Representations ◽  
Five Axis ◽  
Face Grinding ◽  
Tool Grinding

Grinding the helical surfaces in end-mill cutters using two-axis CNC machines is well investigated in literature. However, the grinding wheels do not have explicit geometric representations and the produced helical angles differ from the designed values. Moreover, to the best knowledge of the authors, no reliable and robust algorithm exists to grind generic shape cutters with constant normal rake angles. Thus, the first part of this work introduces a five-axis grinding process that keeps the normal rake angle constant along the rake face. The parameters that affect the shape of the tool flutes are also analyzed and studied in this part. These parameters are then optimized in the second part to obtain optimum wheel shapes grinding the tool flutes along optimum paths. Overall, the grinding process proposed grinds the tool flutes with close matching to the designed ones and replaces the complex wheel shapes commonly used by simple prismatic ones.

Milling Force Prediction Model for Five-Axis Machining of Freeform Surface Considering Mesoscopic Size Effect

2021 ◽  
Vol 143 (9) ◽  
Author(s):  
Minglong Guo ◽  
Zhaocheng Wei ◽  
Minjie Wang ◽  
Jia Wang ◽  
Shengxian Liu
Keyword(s):  
Dislocation Density ◽  
Size Effect ◽  
Prediction Model ◽  
Cutting Force ◽  
Freeform Surface ◽  
End Mill ◽  
Ball End Mill ◽  
Milling Force ◽  
Force Prediction ◽  
Five Axis

Abstract The core parts with the characteristic of freeform surface are widely used in the major equipment of various fields. Cutting force is the most important physical quantity in the five-axis CNC machining process of core parts. Not only in micro-milling, but also in macro-milling, there is also an obvious size effect, especially in medium- and high-speed milling, which is frequently ignored. In this paper, the milling force prediction model for five-axis machining of a freeform surface with a ball-end mill considering the mesoscopic size effect is established. Based on the characteristics of cutting thickness in macro-milling, a new dislocation density correction form is proposed, and a new experiment is designed to identify the dislocation density correction coefficient. Therefore, the shear stress calculated in this paper not only reflects the cutting dynamic mechanical characteristics but also considers the mesoscopic size effect. A linear function is proposed to describe the relationship between friction coefficient and cutting speed, cutter rake angle, and cutting thickness. Considering cutter run-out, the micro-element cutting force in the shear zone and plough zone are analyzed. The cutting geometry contact between the freeform surface and the ball-end mill is analyzed analytically by the space limitation method. Finally, the total milling force is obtained by summing all the force vectors of cutting edge micro-elements within the in-cut cutting edge. In the five-axis machining experiment of freeform surface, the theoretically predicted results of milling forces are in good agreement with the measured results in trend and amplitude.

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