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.

A Model of Cutting Forces for Ball End Mill in High Speed Machining

2010 ◽  
Vol 97-101 ◽  
pp. 3108-3112
Author(s):  
Bing Yan ◽  
Chao Hui Xu ◽  
Wei Wang
Keyword(s):  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
High Speed Machining ◽  
End Mill ◽  
Cutting Mechanism ◽  
Ball End Mill ◽  
High Speed Cutting ◽  
The Relationship ◽  
Machining Characteristics

The machining characteristics of hardened still for mould and die greatly affect the accuracy and productivity in industry. The physical modeling and simulation of ball end milling is investigated in this paper. The influence of cutting speed to the cutting mechanism in high speed cutting is taken into account and the momentum force of chip is introduced into the model. By analyzing the shape of the chips the relationship between the cutting speed and shear angle is obtained. The model has been tested on 718HH, with appropriate Seco tools. The validation shows that the adjustment between the model and the real force is adequate, both in shape and magnitude.

The Force and Wear of Carbide Mill in Milling Glass

2010 ◽  
Vol 44-47 ◽  
pp. 2617-2621
Author(s):  
Zhi Wei ◽  
Mei Lin Gu ◽  
Yu Tao Wang ◽  
Tong Hui Li
Keyword(s):  
Tool Wear ◽  
Quartz Glass ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
End Mill ◽  
Ball End Mill ◽  
Milling Force ◽  
Milling Parameters ◽  
The Relationship ◽  
Cutting Experiments

The force and wear of carbide ball-end mill when quartz glass is milled in the dry state has been studied. Cutting experiments have been investigated for different cutting parameters. The relationship between milling force and cutting conditions has been analyzed. Mechanism and patterns of tool wear has also been studied. A group of reasonable milling parameters have been achieved to mill quartz glass using carbide ball-end mill and tool wear can be delayed in the selected group of cutting parameters.

Modeling and Simulation of Milling Force in Virtual Numerical Control Milling Process

2008 ◽  
Vol 392-394 ◽  
pp. 697-702
Author(s):  
Xiu Lin Sui ◽  
Jia Tai Zhang ◽  
Jiang Hua Ge ◽  
Ya Ping Wang ◽  
H. Yuan
Keyword(s):  
Modeling And Simulation ◽  
Chip Thickness ◽  
Milling Process ◽  
Cutting Edge ◽  
Numerical Control ◽  
Force Model ◽  
End Mill ◽  
Ball End Mill ◽  
Milling Force ◽  
Milling Force Model

A parameter equation based on cutting edge of ball-end mill is set up by analyzing the parameters of ball-end mill influence the milling force in virtual NC milling process. The relationship among elemental cutting force, instantaneous radial chip thickness and cutting edge length is analyzed, and the dynamic milling force of ball-end mill at arbitrary feed direction is established. The milling force parameter model by quadratic regression equation in different cutting conditions is built. Through experiments in NC machining center and using orthogonal combination and principal components analysis, the regression coefficients are calculated. The correctness of milling force model is testified by experiments. All these can provide theoretical basis for physics modeling and simulation of virtual numerical control milling.

scholarly journals Nickel-Based Alloy Dry Milling Process Induced Material Softening Effect

Materials ◽  
2020 ◽  
Vol 13 (17) ◽  
pp. 3758 ◽  
Author(s):  
Jun Zha ◽  
Zelong Yuan ◽  
Hangcheng Zhang ◽  
Yipeng Li ◽  
Yaolong Chen
Keyword(s):  
High Speed ◽  
Softening Temperature ◽  
Milling Process ◽  
Dry Milling ◽  
Milling Force ◽  
Softening Effect ◽  
Milling Temperature ◽  
Nickel Based Alloy ◽  
Alloy Softening ◽  
Milling Forces

Improving the cutting efficiency is the major factor for improving the processing of nickel-based alloys. The novelty of this research is the calibrated SiAlON ceramic tool dry milling nickel-based alloy process. Firstly, the nickel-based alloy dry milling process was analyzed through the finite element method, and the required milling force and temperature were deduced. Then, several dry milling experiments were conducted with the milling temperature, and the milling force was monitored. The change in cutting speeds was from 400 m/min to 700 m/min. Experimental results verified the reduction of the dry milling force hypothesized by the simulation. The experiment also indicated that with a cut depth of 0.3 mm, cut width of 6 mm, and feed per tooth of 0.03 mm/z, when milling speed exceeded 527.52 m/min, the milling force began to decrease, and the milling temperature exceeded the nickel-based alloy softening temperature. This indicated that easy cutting could be realized under high-speed dry milling conditions. The interpolation curve about average temperature and average milling forces showed similarity to the tensile strength reduction with the rise of temperature.

scholarly journals Effect of High Speed Milling Process Parameters on the Milling Force and Surface Topography of AM50A Magnesium Alloy

2018 ◽  
Vol 36 (1) ◽  
pp. 124-131
Author(s):  
Hongji Zhang ◽  
Yuanyuan Ge ◽  
Hong Tang ◽  
Yaoyao Shi ◽  
Zengsheng Li
Keyword(s):  
Magnesium Alloy ◽  
Surface Quality ◽  
High Speed ◽  
Milling Process ◽  
Spindle Speed ◽  
Feed Speed ◽  
Milling Force ◽  
High Speed Milling ◽  
Milling Parameters

Within the scope of high speed milling process parameters, analyzed and discussed the effects of spindle speed, feed rate, milling depth and milling width on milling forces in the process of high speed milling of AM50A magnesium alloy. At the same time, the influence of milling parameters on the surface roughness of AM50A magnesium alloy has been revealed by means of the measurement of surface roughness and surface micro topography. High speed milling experiments of AM50A magnesium alloy were carried out by factorial design. Form the analysis of experimental results, The milling parameters, which have significant influence on milling force in high speed milling of AM50A magnesium alloy, are milling depth, milling width and feed speed, and the nonlinear characteristics of milling force and milling parameters. The milling force decreases with the increase of spindle in the given mill parameters. For the effects of milling parameters on surface quality of the performance, in the milling depth and feeding speed under certain conditions with the spindle speed increases the surface quality of AM50A magnesium alloy becomes better with the feed speed increases the surface quality becomes poor. When the spindle speed is greater than 12000r/min, the milling depth is less than 0.2mm, and the feed speed is less than 400mm/min, the milling surface quality can be obtained easily.

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.

Chatter Stability of Micro-Milling by Considering the Centrifugal Force and Gyroscopic Effect of the Spindle

2019 ◽  
Vol 141 (11) ◽  
Author(s):  
Xiaohong Lu ◽  
Zhenyuan Jia ◽  
Shengqian Liu ◽  
Kun Yang ◽  
Yixuan Feng ◽  
...  
Keyword(s):  
Centrifugal Force ◽  
High Speed ◽  
Beam Theory ◽  
Milling Process ◽  
System Structure ◽  
Micro Milling ◽  
Gyroscopic Effect ◽  
Good Surface ◽  
Receptance Coupling ◽  
Milling Tool

Abstract In the micro-milling process, the minimization of tool chatter is critical for good surface finish quality. The analysis of chatter requires an understanding of the milling tool as well as the dynamics of milling system structure. Frequency response function (FRF) at the micro-milling tool point reflects dynamic behavior of the whole micro-milling machine–spindle–tool system. However, the tool point FRF of micro-milling cannot be obtained directly through the hammering test. To solve the problem, the authors get the FRF of the spindle system based on the rotating Timoshenko beam theory and the receptance coupling substructure analysis (RCSA), and the bearing characteristics are added into the spindle model through structural modification. Then, the centrifugal force and gyroscopic effect caused by the high-speed rotation of the micro-milling spindle are considered to better simulate the real scenario and increase the accuracy of modal parameters. The method has general usage and can be applied to all the micro-milling tools under which only the spindle dimension, bearing characteristics, and contact parameters need to be changed.

A Comparison of the Simulated Dynamics of Various Models Used to Predict Undeformed Chip Thickness in High-Speed Low-Radial-Immersion Milling Processes

2013 ◽  
Author(s):  
Josiah A. Bryan ◽  
Roger C. Fales
Keyword(s):  
High Speed ◽  
Chip Thickness ◽  
Milling Process ◽  
Precision Machining ◽  
Traditional Model ◽  
Cnc Milling ◽  
Undeformed Chip Thickness ◽  
Milling Tool ◽  
Tool Damage ◽  
Low Radial Immersion

Various models have been proposed to estimate the undeformed thickness of chips produced by a CNC milling tool, in order to calculate the forces acting on the tool. The choice of model significantly affects the simulated dynamics of the tool, thereby affecting the dynamic stability of the simulated process and whether or not chatter occurs in a given cutting scenario. Simulations of the dynamics of the milling process can be used to determine the conditions at which chatter occurs, which can lead to poor surface finish and tool damage. The dynamics of a traditional model and a more detailed numerical model are simulated here with particular emphasis on the differences in their chatter bifurcation points. High-speed, low-radial-immersion milling processes are simulated because of their application in industrial high-precision machining.

Sign in / Sign up

Export Citation Format

Share Document