Influence Characteristics of Cutting-Contact Stress on the Wear of Milling Cutter in High Speed Ball-End Milling Hardened Steel

2012 ◽  
Vol 500 ◽  
pp. 192-197
Author(s):  
Bin Jiang ◽  
Pei Yi Zhao ◽  
Yong Zhong Wang ◽  
Yi Hang Fan
Keyword(s):  
Wear Rate ◽  
Contact Stress ◽  
High Speed ◽  
End Milling ◽  
Cutting Parameters ◽  
Hardened Steel ◽  
Curvature Radius ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Pressure Stress

Adopted the cutting-contact model of high speed ball-end milling hardened steel surfaces, researched distribution characteristics of cutting-contact stress; by researching the influence of the distribution of this stress on cutter wear, clarified the influence theory of milling pattern and cutting parameters on initial wear of milling cutter. By using the method of climbing, conventional milling alternating and changing cutting parameters, verified the influence of milling pattern and cutting parameters on initial wear pattern. The result showed that, initial wear mechanism of high speed milling hardened steel is an interaction of multiple wear mechanisms under the effect of friction and alternating pressure stress, by using conventional milling can significantly reduce concave curvature radius of hardened steel, the contact stress of blade area and front, rear flank, inhibit crushing and wear rate of the milling cutter surfaces. Under this condition, by increasing rotation speed and reducing the feed per blade, will further increase the strength of this effect, and achieve the purpose of reducing the initial wear, inhibiting the wear rate and extending the cutters life.

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.

Experiment Research of Cutter Edge and Cutting Parameters Influence on Machined Surface Roughness for High Speed Milling Hardened Steel

2010 ◽  
Vol 136 ◽  
pp. 86-90 ◽  
Author(s):  
Wei Zhang ◽  
Min Li Zheng ◽  
Ming Ming Cheng ◽  
Quan Wan
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Parameters ◽  
Hardened Steel ◽  
Machined Surface ◽  
High Speed Milling ◽  
Ball End Milling ◽  
Edge Radius ◽  
Machined Surface Roughness

By using experiment cutter edge topography obtained by super depth three-dimension microscope, fits the cutter edge curve and calculate experiment cutter edge radius value; by high speed milling hardened steel experiment, individually researches cutter edge and cutting parameters influence on machined surface in high speed milling hardened steel with end-milling cutter and ball-end milling cutter. The experiment analysis results show that under the same cutting parameters condition, machined surface roughness in high speed end-milling cutter milling is better than in high speed ball-end milling; within experiment selected cutting parameter range, cutter edge radius is the main influence factor on machined surface roughness in high speed end- milling hardened steel, while the influence on machined surface roughness in high speed ball-end milling hardened steel is not obvious. In end-milling, when edge radius and milling depth are in the same order magnitude or the difference is not obvious, milling depth should be a little bigger than selected cutter edge radius value.

Experiment Research of Cutter Edge and Cutting Parameters Influence on Machined Surface Roughness for High Speed Milling Hardened Steel

2013 ◽  
Vol 670 ◽  
pp. 70-75 ◽  
Author(s):  
Wei Zhang ◽  
M.L. Zheng ◽  
M.M. Cheng ◽  
W.T. Wang
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Parameters ◽  
Hardened Steel ◽  
Machined Surface ◽  
High Speed Milling ◽  
Ball End Milling ◽  
Edge Radius ◽  
Machined Surface Roughness

By using experiment cutter edge topography obtained by super depth three-dimension microscope, fits the cutter edge curve and calculate experiment cutter edge radius value; by high speed milling hardened steel experiment, individually researches cutter edge and cutting parameters influence on machined surface in high speed milling hardened steel with end-milling cutter and ball-end milling cutter. The experiment analysis results show that under the same cutting parameters condition, machined surface roughness in high speed end-milling cutter milling is better than in high speed ball-end milling; within experiment selected cutting parameter range, cutter edge radius is the main influence factor on machined surface roughness in high speed end- milling hardened steel, while the influence on machined surface roughness in high speed ball-end milling hardened steel is not obvious. In end-milling, when edge radius and milling depth are in the same order magnitude or the difference is not obvious, milling depth should be a little bigger than selected cutter edge radius value.

Dynamics Characteristics of High Speed Ball-End Milling Cutter for Machining Hardened Steel

2010 ◽  
Vol 455 ◽  
pp. 127-131
Author(s):  
Bin Jiang ◽  
Min Li Zheng ◽  
Jun Zhou ◽  
D.H. Xia
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
End Milling ◽  
Hardened Steel ◽  
Milling Cutter ◽  
High Speed Milling ◽  
Ball End Milling ◽  
Modal Characteristics ◽  
Dynamic Cutting Force ◽  
Cutting Vibration

In order to depress cutter vibration caused by high hardness and periodic change of cutting force in high speed milling complex surface, investigated the modal characteristics of ball-end milling cutter through the modal analysis and transient analysis. Using the models of dynamic cutting force and cutting vibration, acquired dynamics characteristics of high speed ball-end milling cutter by the spectrum analysis of dynamic cutting force, simulation analysis of cutting vibration and experiment of high speed milling hardened steel. Results indicate that high speed ball-end milling energy concentrates in few special frequencies, the rotational speed and the numbers of cutter teeth determine the fundamental frequency. High speed ball-end milling cutter easily makes radial bending vibration by the lower modal characteristics, the overhang and inclination angle of cutter affect its dynamics characteristics significantly, and the modal parameters and vibration model of cutter acquired by step response method have higher credibility.

Optimal design of helical flute of irregular tooth end milling cutter based on particle swarm optimization algorithm

2021 ◽  
pp. 095440622110420
Author(s):  
Haibin Yu ◽  
Minli Zheng ◽  
Wei Zhang ◽  
Wanying Nie ◽  
Tianchen Bian
Keyword(s):  
Particle Swarm Optimization ◽  
High Speed ◽  
End Milling ◽  
Dynamic Balance ◽  
Dynamic Performance ◽  
Particle Swarm ◽  
Curvature Radius ◽  
Swarm Optimization ◽  
Milling Cutter ◽  
Helical Flute

Due to the variable pitch angle and helix angle of the irregular tooth end milling cutter, the mass of the integral end milling cutter is eccentric, and the high stability and precision design of the irregular tooth end milling cutter is still a challenge. Aiming at the influence of dynamic balance of irregular tooth end milling cutter which can not be ignored in high-speed milling, the parameterized design of radial section of irregular tooth end milling cutter was carried out. Based on the space transformation law of the centroid of helical flute, a new method for calculating the centroid coordinate of end milling cutter was put forward, and a general mathematical model of eccentricity of integral end milling cutter was given. It was proved that this model could accurately calculate the centroid position and eccentricity of the end milling cutter. The influence of pitch difference angle and helix difference angle on eccentricity of end milling cutter was studied and analyzed. The particle swarm optimization (PSO) algorithm was creatively applied to optimize the helical flute shape of the end milling cutter, the curvature radius of helical flute curve is optimized, so that the centroid coordinate is infinitely close to the origin of coordinate. The number of iterations was set to 200. In the 32nd iteration, the result approached to infinitesimal, the final function converged, and obtained the groove curvature radius of the milling cuter with the smallest eccentricity. The optimized eccentricity of the end milling cutter is infinitesimal, which can make the vibration damping performance of the end milling cutter be fully developed. On the basis of ensuring the same cutting performance, the cutting tool unbalance was effectively reduced and the dynamic performance of milling cutter was further improved.

Physical Field Evaluation Model of High Speed Ball-End Milling Hardened Steel

2012 ◽  
Vol 426 ◽  
pp. 122-125 ◽  
Author(s):  
Bin Jiang ◽  
D.H. Xia ◽  
Min Li Zheng ◽  
Y. Li ◽  
X.C. Liu
Keyword(s):  
High Speed ◽  
End Milling ◽  
Evaluation Model ◽  
Safety Margin ◽  
Field Evaluation ◽  
Hardened Steel ◽  
Physical Field ◽  
Field Analysis ◽  
Ball End Milling ◽  
The Impact

Based on the experiment of high speed ball-end milling hardened steel, investigated the distribution characteristics of cutting force and cutting heat and wearing character of cutter, and set up analysis model of cutter physical field. Using failure criterion and safety margin of cutter, founded physical field evaluation model of high speed ball-end milling cutter. By means of physical field analysis and experiment, explored the influence of cutting parameters on cutting property during cutter wear. Results indicate that the method of safety margin and physical field evaluation model can evaluate cutting property of cutter effectively, the impact of feed per tooth on physical field and safety margin is noticeable, and high speed and small feed are helpful to improve safety margin and cutting performance of cutter.

Cutting Thickness of High Speed Ball-End Milling Hardened Steel

2012 ◽  
Vol 426 ◽  
pp. 24-27
Author(s):  
Shu Cai Yang ◽  
Bin Jiang ◽  
H.Y. Li ◽  
M.L. Zheng ◽  
S.J. Wang
Keyword(s):  
High Speed ◽  
End Milling ◽  
Chip Thickness ◽  
Surface Damage ◽  
Transformation Process ◽  
Hardened Steel ◽  
Machined Surface ◽  
Element Analysis ◽  
Ball End Milling ◽  
Adiabatic Shearing

In order to solve the problem of machined surface damage and machining efficiency decline that caused by the decrease of effective cutting thickness in high speed ball-end milling hardened steel, using high speed cutting adiabatic shearing model, analyzed the adiabatic shearing deformation on hardened steel, and proposed the criterion of chip separating position. Analyzed the force in the transformation process from cutting to plowing, the influence of cutter deformation on cutting thickness was studied, and established the minimum cutting thickness model. Having done finite element analysis of cutter and experiment of high speed milling hardened steel, the validity of the minimum cutting thickness model was proved. The results show that cutting thickness changes from small to large, and then from large to small under the influence of cutting trajectory and tool edge radius. The deformation of cutter leads to the increase of the minimum cutting thickness, and further enhances chip thickness thinning effect. High feed can compensate cutting thickness thinning and the minimum cutting thickness model provides an effective way to restrain the damage of machined surface and cutter caused by cutter plowing.

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