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.

Grinding Process of Ball End Milling Cutter Flank

2018 ◽  
Vol 764 ◽  
pp. 383-390 ◽  
Author(s):  
Quan Qi Xin ◽  
Tai Yong Wang ◽  
Zhi Qiang Yu ◽  
Hong Yan Hu
Keyword(s):  
Mathematical Model ◽  
End Milling ◽  
Cutting Edge ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Position And Orientation ◽  
The Mathematical Model

In this paper, the mathematical model of "S" - shaped cutting-edge curve is optimized, and the position and orientation of the grinding wheel of the first and second flank of the ball end milling cutter are calculated, The correctness of the algorithm is verified by VERICUT simulation.

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.

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.

An Investigation of Wear of Ball End Milling Cutter for High-Speed Milling of Hardened Cr12MoV Steel

2014 ◽  
Vol 800-801 ◽  
pp. 475-478 ◽  
Author(s):  
Cai Xu Yue ◽  
Hui Ze Feng ◽  
Jing Ma ◽  
Zhao Nan Zhong ◽  
Fei Liu
Keyword(s):  
Tool Life ◽  
High Speed ◽  
End Milling ◽  
Helix Angle ◽  
Rake Angle ◽  
Milling Cutter ◽  
High Speed Milling ◽  
Ball End Milling ◽  
Edge Stiffness

The high-speed milling experiments on hardened Cr12MoV steel were carried out with ball end milling cutter of different edge parameters. The influences of helix angle and rake angle on tool life and surface roughness were focused on. Meanwhile, the impacts of edge parameters on cutting edge stiffness and flank wear were analyzed on the condition of high-speed milling. It carried out that smaller helix angle and negative rake angle selected during high speed milling can guarantee quality of surface manufactured as well as longer tool life.

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.

Experimental Study on Wear and Fracture of Ball-End Milling Cutter in High Speed Machining Stainless Steel 0Cr13Ni4Mo

2013 ◽  
Vol 770 ◽  
pp. 3-6
Author(s):  
Dong Chen ◽  
Guang Yu Tan ◽  
Guang Jun Liu ◽  
Guang Hui Li
Keyword(s):  
Experimental Study ◽  
Stainless Steel ◽  
High Speed ◽  
End Milling ◽  
Cutting Edge ◽  
High Speed Photography ◽  
High Speed Machining ◽  
Rake Face ◽  
Milling Cutter ◽  
Ball End Milling

An experimental study on wear and fracture of ball-end milling cutter in high speed machining martensitic stainless steel 0Cr13Ni4Mo is studied in this work. Through the SEM micrographs and energy spectrum analysis of the wear pattern of the rake face, severe coating spalling is found near the main cutting edge. Fracture is seen on the entire cutting edge, in which micro-chipping occurs on the both ends of the cutting edge, and chipping occurs in the middle of the cutting edge and is the conchoidal spalling on the rake face. Combined with the high-speed photography of the milling process, the fracture area is consistent with the chip-adhesion area.

scholarly journals Optimization of Texture Density Distribution of Carbide Alloy Micro-Textured Ball-End Milling Cutter Based on Stress Field

2020 ◽  
Vol 10 (3) ◽  
pp. 818
Author(s):  
Minli Zheng ◽  
Chunsheng He ◽  
Shucai Yang
Keyword(s):  
Wear Resistance ◽  
Stress Field ◽  
Density Distribution ◽  
Titanium Alloys ◽  
Contact Area ◽  
End Milling ◽  
Variable Density ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Texture Density

The insertion of micro-textures plays a role in reducing friction and increasing wear resistance of the cutters, which also has a certain impact on the stress field of the cutter during milling. Therefore, in order to study the mechanisms of friction reduction and wear resistance of micro-textured cutters in high speed cutting of titanium alloys, the dynamic characteristics of the instantaneous stress field during the machining of titanium alloys with micro-textured cutters were studied by changing the distribution density of the micro-textures on the cutter. First, the micro-texture insertion area of the ball-end milling cutter was theoretically analyzed. Then, variable density micro-textured ball-end milling cutters and non-texture cutters were used to cut titanium alloy, and the mathematical model of milling force and cutter-chip contact area was established. Then, the stress density functions of different micro-texture density cutters and non-texture cutters were established to simulate the stress fields of variable density micro-textured ball-end milling cutters and non-texture cutters. Finally, the genetic algorithm was used to optimize the variable density distribution of micro-textured cutters in which the instantaneous stress field of the cutters was taken as the optimization objective. The optimal solution for the variable density distribution of the micro-textured cutter in the cutter-chip tight contact area was obtained as follows: the texture distribution densities in the first, second, and third areas are second, and third areas are 0.0905, 0.0712, and 0.0493, respectively.

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