Geometric Simulation of Ball-End Milling Operations

2000 ◽  
Vol 123 (2) ◽  
pp. 177-184 ◽  
Author(s):  
B. M. Imani ◽  
M. A. Elbestawi
Keyword(s):  
Geometric Modeling ◽  
End Milling ◽  
Cnc Machining ◽  
Final Model ◽  
Ball End Milling ◽  
Milling Operations ◽  
Geometric Simulation ◽  
Swept Volume ◽  
Feed Mark ◽  
Chip Geometry

In this paper, B-rep solid modeling techniques are used to deal with geometric modeling issues encountered in ball-end milling simulation. The precise B-rep model of the cutter swept volume is developed using advanced sweeping/skinning techniques. Semi-finishing operations are simulated by performing consecutive Boolean operations between the updated part and swept volume. The instantaneous chip geometry is accurately and reliably extracted from the B-rep model of the updated part. Also, the material removal in ball-end milling is precisely simulated for finishing operations, in order to construct the feed-mark and scallop geometries. The validity of the final model is confirmed by comparing the predicted feed-mark profile with experimental measurements. The system developed can be used to verify and optimize NC codes, thus contributing to improving reliability, accuracy, and productivity in CNC machining.

Research on Modeling of Ball-End Cutter for Virtual NC Machining

2010 ◽  
Vol 37-38 ◽  
pp. 1050-1055
Author(s):  
Jiang Hua Ge ◽  
Ping Zhang ◽  
Xiu Lin Sui ◽  
Ping Zhao
Keyword(s):  
Physical Simulation ◽  
End Milling ◽  
Nc Machining ◽  
Surface Model ◽  
Functional Surface ◽  
Geometric Information ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Machining System ◽  
Geometric Simulation

In this paper, a new mathematical model and modeling method of ball-end milling cutter which satisfies the request of physical simulation in virtual NC machining system are proposed. The accurate expressions of the cutting edge are presented. The precise functional surface model of ball-end cutter is developed. And the 3-D visualization for ball-end milling cutter in virtual NC machining is implemented. The model can provide necessary and accurate geometric information for physical simulation and has been applied in milling force simulation. It laid the foundation for integration of geometric simulation and physical simulation.

Modelling Power Consumption in Ball-End Milling Operations

2011 ◽  
Vol 26 (5) ◽  
pp. 746-756 ◽  
Author(s):  
G. Quintana ◽  
J. Ciurana ◽  
J. Ribatallada
Keyword(s):  
Power Consumption ◽  
End Milling ◽  
Ball End Milling ◽  
Milling Operations

Study on Machining Error in Ball End Milling of Spherical Surface

2009 ◽  
Vol 407-408 ◽  
pp. 456-459 ◽  
Author(s):  
Hisataka Tanaka ◽  
Masahiko Sato ◽  
Hiroshi Yoshida ◽  
Satoki Ohta ◽  
Susumu Okamura
Keyword(s):  
End Milling ◽  
Spherical Surface ◽  
Position Angle ◽  
Machining Error ◽  
Machined Surface ◽  
Ball End Milling ◽  
Machining Errors ◽  
Series Of Experiments ◽  
Chip Geometry ◽  
Tool Deflections

This paper presents the results of a series of experiments performed to examine the validity of a theoretical analysis for evaluation of machining error in ball end milling of spherical surface. In the analysis, the trochoidal paths of cutting edges are considered in the evaluation of chip geometry. The cutting forces are evaluated based on the theory of oblique cutting. The machining errors resulting from cutting force induced tool deflections are calculated at various parts of the machined surface. The experiments are carried out at various cutting conditions for convex spherical surface, and the influences of cutting mode and milling position angle on machining error are examined.

Analytical Modeling of Chip Geometry in High-Speed Ball-End Milling on Inclined Inconel-718 Workpieces

2015 ◽  
Vol 137 (1) ◽  
Author(s):  
Harshad A. Sonawane ◽  
Suhas S. Joshi
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
End Milling ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Shear Angle ◽  
Analytical Models ◽  
Ball End Milling ◽  
Cutting Mechanisms ◽  
Chip Geometry

Most often contoured surfaces inclined at several inclinations are generated using ball-end milling of aerospace and automobile components. It is understood that the chip morphology and the corresponding cutting mechanisms change with a change in the tool-workpiece interactions on inclined surfaces. Analytical predictive models to accurately evaluate the undeformed and deformed geometries of chip in ball-end milling are not available. Therefore, this work presents development of analytical models to predict the cutting tool-workpiece interaction as the workpiece inclination changes, in terms of undeformed and deformed chip cross sections. The models further evaluate instantaneous shear angle along any cross section of the tool-work interaction on a ball-end cutter in a milling operation. The models illustrate evaluation of a chip segment and mechanism of its formation in ball-end milling on an inclined work surface. It is observed that the chip dimensions, except deformed chip thickness, increase with an increase in the workpiece inclination angle. Also, a higher workpiece inclination results into an easy flow of the deformed chip over the cutting tool flank, which leads to a higher shear angle during the cut. The predictive chip geometry models corroborate 90% to the experimental results obtained at various workpiece inclinations.

Avoiding neural network fine tuning by using ensemble learning: application to ball-end milling operations

2011 ◽  
Vol 57 (5-8) ◽  
pp. 521-532 ◽  
Author(s):  
Andres Bustillo ◽  
José-Francisco Díez-Pastor ◽  
Guillem Quintana ◽  
César García-Osorio
Keyword(s):  
Neural Network ◽  
Ensemble Learning ◽  
End Milling ◽  
Fine Tuning ◽  
Ball End Milling ◽  
Milling Operations

Dynamics and Stability of Five-Axis Ball-End Milling

2010 ◽  
Vol 132 (2) ◽  
Author(s):  
Erdem Ozturk ◽  
Erhan Budak
Keyword(s):  
Time Domain ◽  
End Milling ◽  
Milling Process ◽  
Ball End Milling ◽  
Part Quality ◽  
Stability Diagrams ◽  
Milling Operations ◽  
The Stability ◽  
Milling Dynamics ◽  
Five Axis

Being one of the most important problems in machining, chatter vibrations must be avoided as they result in high cutting forces, poor surface finish, and unacceptable part quality. Using stability diagrams is an effective method to predict chatter free cutting conditions. Although there have been numerous works in milling dynamics, the stability of five-axis ball-end milling has not been studied in detail. In this paper, the stability of the five-axis ball-end milling is analyzed using analytical (frequency domain), numerical (time-domain), and experimental methods. The models presented consider 3D dynamics of the five-axis ball-end milling process including the effects of all important process parameters such as the lead and tilt angles. Both single- and multi-frequency solutions are presented. Unlike other standard milling cases, it is observed that adding multi-frequency effects in the solution has marginal influence on the stability diagrams for five-axis ball-end milling operations due to effects of the ball-end milling geometry on the engagement region, thus, on the directional coefficients. The stability limits predicted by single- and multi-frequency methods are compared with time-domain simulations and experiments. Using the models and experimental results, the effects of the lead and tilt angles on the stability diagrams are also shown. The presented models can be used in analysis of five-axis ball-end milling dynamics as well as in the selection of the milling conditions for increased stability.

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