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 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.

Modelling and characterisation of roughness of moulds produced by high-speed machining with ball-nose end mill

2016 ◽  
Vol 231 (6) ◽  
pp. 933-944 ◽  
Author(s):  
Marcelo Ferreira Batista ◽  
Alessandro Roger Rodrigues ◽  
Reginaldo Teixeira Coelho
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Surface Damage ◽  
Double Effect ◽  
Hardened Steel ◽  
Numerical Control ◽  
High Speed Machining ◽  
End Mill ◽  
Kinematic Singularity ◽  
Dimensional Errors

Cusps and scallops of hardened steel moulds produced by high-speed milling using a ball-nose end mill were mathematically modelled, characterised by microscopy and experimentally validated. The experimental results show that the part material is crushed or ploughed near the cutter centre, where the cutting speed is very low. This kinematic singularity, associated with tool feed, compresses and bends the ball-nose end mill axially. Because of this double effect, the end mill marks on the part at the end of the milling path cause surface damage and dimensional errors to the hardened mould. A mathematical model may predict the formation of the cusps and scallops and be of use in computer numerical control or computer-aided manufacturing programming to obtain the desired part topography.

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.

Prediction of Surface Roughness in High Speed Machining of Inconel 718

2011 ◽  
Vol 264-265 ◽  
pp. 1193-1198
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
High Speed Machining

Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.

Optimization of Cutting Conditions with an End Mill According to the Criterion of the Smallest Amplitude of Vibration

2021 ◽  
Vol 1037 ◽  
pp. 239-244
Author(s):  
Dmitriy Y. Topolov ◽  
Igor S. Boldyrev
Keyword(s):  
Vibration Amplitude ◽  
End Milling ◽  
Cutting Speed ◽  
Forced Vibrations ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
End Mill ◽  
Optimal Values ◽  
The Relationship

The article discusses the issues of chatter damping during milling. The relationship between the amplitude of forced vibrations and the cutting speed has been established. The choice of the optimal values ​​of the cutting condition during end milling is proposed to ensure the minimum vibration amplitude.

Experimental Research of Effective Cutting Speed Influence on Surface Roughness in Ball End Milling of C45 Material with Hardness 54 HRC

2015 ◽  
Vol 809-810 ◽  
pp. 27-32
Author(s):  
Sandor Ravai-Nagy ◽  
Ioan Paşca ◽  
Mircea Lobontiu ◽  
Mihai Banica
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Cutting Speed ◽  
Curved Surfaces ◽  
End Mill ◽  
Ball End Mill ◽  
Frequent Use ◽  
Optimum Cutting ◽  
End Mills ◽  
The Cost

In the context of the increasingly frequent use of curved surfaces in the design of products surrounding us, ball end mills are at present the only usable tools in the cutting of complex surfaces, either concave or convex. This aspect, once correlated with the need to reduce the surface roughness, which means an increase in the cost of processing, directs our research to those on the milling with ball end mill. In this way we can identify the optimum cutting data in terms of costs to ensure the prescribed surface roughness. The paper is based on a set of experiments on the correlation of roughness with the parameters of the cutting process, for the C45 material treated with heat at 54HRC. The paper presents a part of a complex industrial research in this area and is complementary to the published works [1, 2]

Evaluation of the Effect of High Speed Machining on Tapping

1994 ◽  
Vol 116 (4) ◽  
pp. 457-462 ◽  
Author(s):  
J. S. Agapiou
Keyword(s):  
Shear Strength ◽  
Steady State ◽  
High Speed ◽  
Cutting Speed ◽  
Hole Diameter ◽  
Roll Forming ◽  
High Speed Machining ◽  
High Speeds ◽  
Spindle Rotation ◽  
The Relationship

This paper summarizes tapping characteristics at speeds as high as 9,000 rpm (180 m/min surface speed) as compared to traditional tapping done at speeds from 500 to 1,500 rpm (20–30 m/min). High speed tapping was achieved by synchronizing the spindle rotation and the feed motion of a specially built machine at extremely high speeds and acceleration/deceleration rates. This investigation analyzes the performance of roll and cut tap geometries in the high speed tapping of 319 aluminum. The torque required by the different tap geometries at several speeds and percent threads combination is evaluated. The relationship between pretapped hole diameter and minor diameter of the thread and the estimation of percent thread are analyzed. The thread quality generated at high speeds is also evaluated. It is shown that the cutting speed does not affect the steady state torque and the shear strength. The torque for roll forming taps is higher than that for cut taps. The shear strength of roll forming threads increased with percent thread.

scholarly journals Experimental Investigation on the Cutting Mechanism of Oxygen Free Copper in Cutting Speeds Ranging from 1 m/s to 210 m/s

2013 ◽  
Vol 797 ◽  
pp. 208-213 ◽  
Author(s):  
Jun Shinozuka
Keyword(s):  
High Speed ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Shear Plane ◽  
Friction Angle ◽  
Temperature Fields ◽  
Cutting Mechanism ◽  
Machined Surface ◽  
High Speed Cutting

The orthogonal cutting tests of oxygen free copper with a cutting speed of from 1 m/s to 210 m/s were performed. The effect of the high-speed cutting on the improvement over the quality of the machined surface, which was evaluated by the thickness of the plastic flow layer and the surface roughness, was examined. By employing the simple shear plane model, the cutting mechanism was analyzed. The results were compared with the results for cutting of aluminum alloy obtained previously. For oxygen free copper, the resultant cutting force does not increase in high-speed cutting. However, the friction angle on the tool-chip interface rises clearly in high-speed cutting. This paper discusses the reason for the increase in the friction angle at the tool-chip interface by investigating the stress and temperature fields on the shear plane and the tool-chip interface.

Machinability Improvement by Workpiece Preheating during End Milling AISI H13 Hardened Steel

2011 ◽  
Vol 264-265 ◽  
pp. 888-893
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
High Speed Machining

Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.

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