Comparison of Theoretical and Real Surface Roughness in Case of Ball-End Milling

2017 ◽  
Vol 261 ◽  
pp. 299-304 ◽  
Author(s):  
Balázs Mikó ◽  
Balázs Tóth ◽  
Bálint Varga
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Plane Surface ◽  
Estimation Method ◽  
Free Form ◽  
Surface Finishing ◽  
Depth Of Cut ◽  
Real Surface ◽  
Ball End Milling ◽  
Tool Diameter

In case of free form surface milling the quality of the manufacturing is described by the accuracy of the shape and the surface roughness. The 3D surface finishing milling by ball-end milling cutter is one of the most often used machining technologies. In case of ball-end milling the surface roughness can be described theoretically based on the tool diameter and the density of the tool path, but the experience shows than other parameters have effect on the surface roughness. In the article the effect of the different cutting parameters, like feed (fz), depth of cut (ap) and width of cut (ae), is presented in case of plane surface, and the surface roughness is compared with the theoretical roughness, and an estimation method is presented.

Surface Roughness Prediction in Ball-End Milling Process for Aluminum by Using Air Blow Cutting

2011 ◽  
Vol 418-420 ◽  
pp. 1428-1434 ◽  
Author(s):  
Keerati Karunasawat ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Speed ◽  
Milling Process ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Ball End Milling ◽  
Tool Diameter ◽  
End Milling Process

The objective of this research is to develop the surface roughness and cutting force models by using the air blow cutting of the aluminum in the ball-end milling process. The air blow cutting proposed in order to reduce the use of the cutting fluid. The surface roughness and cuttting force models are proposed in the exponential forms which consist of the cutting speed, the feed rate, the depth of cut, the tool diameter, and the air blow pressure. The coefficients of the surface roughness and cutting force models are calculated by utilizing the multiple regression with the least squared method at 95% significant level. The effects of cutting parameters on the cutting force are investigated and measured to analyze the relation between the surface roughness and the cutting conditions. The experimentally obtained results showed that the cutting force has the same trend with the surface roughness. The surface plots are constructed to determine the optimum cutting condition referring to the minimum surface roughness.

Parameter Optimization of Ball End Milling Process on Inconel 718 Using RSM and TLBO Algorithm

2015 ◽  
Vol 15 (3) ◽  
pp. 293-300 ◽  
Author(s):  
Nandkumar N. Bhopale ◽  
Nilesh Nikam ◽  
Raju S. Pawade
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Tool Path ◽  
End Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Ball End Milling

AbstractThis paper presents the application of Response Surface Methodology (RSM) coupled with Teaching Learning Based Optimization Technique (TLBO) for optimizing surface integrity of thin cantilever type Inconel 718 workpiece in ball end milling. The machining and tool related parameters like spindle speed, milling feed, axial depth of cut and tool path orientation are optimized with considerations of multiple response like deflection, surface roughness, and micro hardness of plate. Mathematical relationship between process parameters and deflection, surface roughness and microhardness are found out by using response surface methodology. It is observed that after optimizing the process that at the spindle speed of 2,000 rpm, feed 0.05 mm/tooth/rev, plate thickness of 5.5 mm and 15° workpiece inclination with horizontal tool path gives favorable surface integrity.

Intelligent Monitoring and Prediction of Surface Roughness in Ball-End Milling Process

2011 ◽  
Vol 121-126 ◽  
pp. 2059-2063 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Angsumalin Senjuntichai
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Prediction Accuracy ◽  
End Milling ◽  
Milling Process ◽  
Ball End Milling ◽  
Roughness Model ◽  
Force Ratio ◽  
Tool Diameter ◽  
End Milling Process

In order to realize the intelligent machines, the practical model is proposed to predict the in-process surface roughness during the ball-end milling process by utilizing the cutting force ratio. The ratio of cutting force is proposed to be generalized and non-scaled to estimate the surface roughness regardless of the cutting conditions. The proposed in-process surface roughness model is developed based on the experimentally obtained data by employing the exponential function with five factors of the spindle speed, the feed rate, the tool diameter, the depth of cut, and the cutting force ratio. The prediction accuracy and the prediction interval of the in-process surface roughness model at 95% confident level are calculated and proposed to predict the distribution of individually predicted points in which the in-process predicted surface roughness will fall. All those parameters have their own characteristics to the arithmetic surface roughness and the surface roughness. It is proved by the cutting tests that the proposed and developed in-process surface roughness model can be used to predict the in-process surface roughness by utilizing the cutting force ratio with the highly acceptable prediction accuracy.

scholarly journals Cutting Force Modeling and Optimization in 3D Plane Surface Machining

1999 ◽  
Author(s):  
Hsi-Yung (Steve) Feng ◽  
Ning Su
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Plane Surface ◽  
Mechanistic Modeling ◽  
Surface Finishing ◽  
Force Model ◽  
Cutting Force Model ◽  
Ball End Milling ◽  
Finishing Machining

Abstract The prediction and optimization of cutting forces in the finishing machining of 3D plane surfaces using ball-end milling are presented in this paper. The cutting force model is developed based on the mechanistic modeling approach. This improved model is able to accurately predict the cutting forces for non-horizontal and cross-feed cutter movements typical in 3D finishing ball-end milling. Optimization of the cutting forces is used to determine both the tool path and the maximum feed rate in 3D plane surface finishing machining. The objective is to achieve highest machining efficiency and to ensure product quality. Experimental results have shown that the cutting force model gives excellent predictions of cutting forces in 3D finishing ball-end milling. The feasibility of the integrated process planning method has been demonstrated through the establishment of optimized process plans for the finishing machining of 3D plane surfaces.

Monitoring of Surface Roughness Based on Cutting Force and Cutting Temperature in Ball-End Milling Process by Utilizing Response Surface Analysis

2015 ◽  
Vol 799-800 ◽  
pp. 324-328
Author(s):  
Panrawee Yaisuk ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Response Surface ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Temperature ◽  
Milling Process ◽  
Depth Of Cut ◽  
Tool Diameter ◽  
End Milling Process

The surface roughness is monitored using the cutting force and the cutting temperature in the ball-end milling process by utilizing the response surface analysis with the Box-Behnken design. The optimum cutting condition is obtained referring to the minimum surface roughness, which is the spindle speed, the feed rate, the depth of cut, and the tool diameter. The models of cutting force ratio and the cutting temperature are proposed and developed based on the experimental results. It is understood that the surface roughness is improved with an increase in spindle speed, feed rate and depth of cut. The cutting temperature decreases with an increase in tool diameter. The model verification has showed that the experimentally obtained surface roughness model is reliable and accurate to estimate the surface roughness.

scholarly journals The Effect of the Feed Direction on the Micro- and Macro Accuracy of 3D Ball-end Milling of Chromium-Molybdenum Alloy Steel

Materials ◽  
2019 ◽  
Vol 12 (24) ◽  
pp. 4038
Author(s):  
Balázs Mikó ◽  
Bálint Varga ◽  
Wojciech Zębala
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Tool Path ◽  
End Milling ◽  
Cutting Parameters ◽  
Machining Process ◽  
Free Form ◽  
Dimensional Error ◽  
Ball End Milling ◽  
Free Form Surfaces

The machining of free form surfaces is one of the most challenging problems in the field of metal cutting technology. The produced part and machining process should satisfy the working, accuracy, and financial requirements. The accuracy can describe dimensional, geometrical, and surface roughness parameters. In the current article, three of them are investigated in the case of the ball-end milling of a convex and concave cylindrical surface form 42CrMo4 steel alloy. The effect of the tool path direction is investigated and the other cutting parameters are constant. The surface roughness and the geometric error are measured by contact methods. Based on the results, the surface roughness, dimensional error, and the geometrical error mean different aspects of the accuracy, but they are not independent from each other. The investigated input parameters have a similar effect on them. The regression analyses result a very good liner regression for geometric errors and shows the importance of surface roughness.

Evaluation of Surface Roughness in Five-Axis Ball-End Milling

2020 ◽  
pp. 21-31
Author(s):  
B.B. Ponomarev ◽  
S.H. Nguyen
Keyword(s):  
Surface Roughness ◽  
Tilt Angle ◽  
End Milling ◽  
Free Form ◽  
Tool Orientation ◽  
Ball End Milling ◽  
Lead Angle ◽  
Tool Tilt Angle ◽  
Five Axis ◽  
Free Form Surfaces

Unlike three-axis machining, five-axis machining allows the end tool or workpiece to be oriented at any angle relative to the machine axis OZ. It can be achieved by changing the values of the tool tilt angle and lead angle relative to the surface normal in the contact zone of the tool surface and the workpiece, taking into account the direction of the table feed. The article presents experimental results of analyzing the influences of tool orientation on transverse roughness during ball end milling using 2-flute and 4-flute 8 mm diameter mills. The analysis the arithmetic mean deviation of the assessed profile at various values of tool tilt angle and lead angle showed that the position of the tool point with a zero cutting speed significantly affects the surface quality. The results of the evaluation of the tool orientation influence on the surface roughness enable the selection of optimal tool orientation angles when developing control programs for end milling of free-form surfaces on five-axis CNC milling machines.

Effect of Tool Tilting Angle on Tool Wear and Surface Roughness in Micro Ball End Milling

2011 ◽  
Vol 325 ◽  
pp. 606-611 ◽  
Author(s):  
Kazuya Hamaguchi ◽  
Yuji Kagata ◽  
Hiroo Shizuka ◽  
Koichi Okuda
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Flank Wear ◽  
End Milling ◽  
Depth Of Cut ◽  
End Mill ◽  
Ball End Mill ◽  
Ball End Milling ◽  
Tilting Angle ◽  
Radial Depth

This paper describes the effect of the tool tilting angle on the tool wear and the surface roughness in micro ball end milling. The cutting tests of hardened stainless steel were carried out by using of the micro ball end mill with radius of 100mm under the conditions of tilting angle from 0° to 45°. The spindle speed was fixed in a constant of 120,000 min-1. The feed per tooth, axial depth of cut and radial depth of cut were also fixed. The flank wear, the surface roughness and the cutting force were investigated. As a result, the maximum width of flank wear of the micro ball end mill tended to decrease with an increase in the tilting angle of spindle. The surface roughness became almost constant not depending on the tilting angle of the spindle.

A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 576 ◽  
pp. 60-63 ◽  
Author(s):  
N.A.H. Jasni ◽  
Mohd Amri Lajis
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Radial Depth ◽  
Aisi D2 ◽  
Coated Carbide

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.

Surface Roughness Identification in End Milling Using Vibration Signals and Fuzzy Clustering

2016 ◽  
Author(s):  
Issam Abu-Mahfouz ◽  
Amit Banerjee ◽  
A. H. M. Esfakur Rahman
Keyword(s):  
Surface Roughness ◽  
Fuzzy Clustering ◽  
Wavelet Transforms ◽  
Fourier Transforms ◽  
End Milling ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Machined Surface ◽  
Vibration Signals

The study presented involves the identification of surface roughness in Aluminum work pieces in an end milling process using fuzzy clustering of vibration signals. Vibration signals are experimentally acquired using an accelerometer for varying cutting conditions such as spindle speed, feed rate and depth of cut. Features are then extracted by processing the acquired signals in both the time and frequency domain. Techniques based on statistical parameters, Fast Fourier Transforms (FFT) and the Continuous Wavelet Transforms (CWT) are utilized for feature extraction. The surface roughness of the machined surface is also measured. In this study, fuzzy clustering is used to partition the feature sets, followed by a correlation with the experimentally obtained surface roughness measurements. The fuzzifier and the number of clusters are varied and it is found that the partitions produced by fuzzy clustering in the vibration signal feature space are related to the partitions based on cutting conditions with surface roughness as the output parameter. The results based on limited simulations are encouraging and work is underway to develop a larger framework for online cutting condition monitoring system for end milling.

Sign in / Sign up

Export Citation Format

Share Document