Prediction of Ball End Milling Forces

1996 ◽  
Vol 118 (1) ◽  
pp. 95-103 ◽  
Author(s):  
G. Yu¨cesan ◽  
Y. Altıntas¸
Keyword(s):  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Cutting Conditions ◽  
Analytic Representation ◽  
Rake Face ◽  
Uncut Chip Thickness ◽  
Ball End Milling ◽  
Helical Flute ◽  
Milling Forces

Mechanics of milling with ball ended helical cutters are modeled. The model is based on the analytic representation of ball shaped helical flute geometry, and its rake and clearance surfaces. It is assumed that friction and pressure loads on the rake face are proportional to the uncut chip thickness area. The load on the flank contact face is concentrated on the in cut portion of the cutting edge. The pressure and friction coefficients are identified from a set of slot ball end milling tests at different feeds and axial depth of cuts, and are used to predict the cutting forces for various cutting conditions. The experimentally verified model accurately predicts the cutting forces in three Cartesian directions.

Cutting Force Prediction of Ball End Milling Based on Fully Voxel Representation of Cutting Edge and Instantaneous Workpiece Shape

2017 ◽  
Author(s):  
Isamu Nishida ◽  
Ryuma Okumura ◽  
Ryuta Sato ◽  
Keiichi Shirase
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Surface Shape ◽  
Uncut Chip Thickness ◽  
Ball End Milling ◽  
Voxel Model ◽  
Voxel Representation ◽  
Milling Forces

A new cutting force simulator has been developed to predict cutting force in ball end milling. This new simulator discretely calculates uncut chip thickness based on a fully voxel representation of the cutting edge and instantaneous workpiece shape. Previously, a workpiece voxel model was used to calculate uncut chip thickness under a complex change of workpiece shape. Using a workpiece voxel model, uncut chip thickness is detected by extracting the voxels removed per cutting edge tooth for the amount of material fed into the cutting edge. However, it is difficult to define the complicated shape of a cutting edge using the workpiece voxel model; the shape of the cutting edge must be defined by a mathematical expression. It is also difficult to model the voxels removed by the cutting edge when the tool posture is non-uniformly changed. We therefore propose a new method to detect uncut chip thickness, one in which both the cutting edge and the instantaneous workpiece shape are fully represented by a voxel model. Our proposed method precisely detects uncut chip thickness at minute tool rotational angles, making it possible to detect the uncut chip thickness between the complex surface shape of the workpiece and the particular shape of the cutting edge. To validate the effectiveness of our proposed method, experimental 5-axis milling tests using a ball end mill were conducted. Estimated milling forces for several tool postures were found to be in good agreement with the measured milling forces. Results from the experimental 5-axis milling validate the effectiveness of our proposed method.

Single Edge Cutting Phenomenon and Instantaneous Uncut Chip Thickness Model of Micro-Ball-End Milling

2011 ◽  
Vol 4 (4) ◽  
pp. 1387-1393 ◽  
Author(s):  
Zhenyu Han ◽  
Xiang Zhang ◽  
Yazhou Sun ◽  
Hongya Fu ◽  
Yingchun Liang
Keyword(s):  
End Milling ◽  
Chip Thickness ◽  
Single Edge ◽  
Uncut Chip Thickness ◽  
Ball End Milling ◽  
Instantaneous Uncut Chip Thickness

A Mechanistic Cutting Force Model for 3D Ball-end Milling

2000 ◽  
Vol 123 (1) ◽  
pp. 23-29 ◽  
Author(s):  
Hsi-Yung Feng ◽  
Ning Su
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Milling Process ◽  
Force Model ◽  
Cutting Force Model ◽  
Ball End Milling ◽  
End Milling Process ◽  
Force Relationship

This paper presents an improved mechanistic cutting force model for the ball-end milling process. The objective is to accurately model the cutting forces for nonhorizontal and cross-feed cutter movements in 3D finishing ball-end milling. Main features of the model include: (1) a robust cut geometry identification method to establish the complicated engaged area on the cutter; (2) a generalized algorithm to determine the undeformed chip thickness for each engaged cutting edge element; and (3) a comprehensive empirical chip-force relationship to characterize nonhorizontal cutting mechanics. Experimental results have shown that the present model gives excellent predictions of cutting forces in 3D ball-end milling.

An Approach to Modeling Cutting Forces in Five-Axis Ball-End Milling of Curved Geometries Based on Tool Motion Analysis

2010 ◽  
Vol 132 (4) ◽  
Author(s):  
Guo Dongming ◽  
Ren Fei ◽  
Sun Yuwen
Keyword(s):  
Motion Analysis ◽  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Axis Orientation ◽  
Undeformed Chip Thickness ◽  
Ball End Milling ◽  
Tool Motion ◽  
Five Axis

The prediction of five-axis ball-end milling forces is quite a challenge due to difficulties of determining the underformed chip thickness and engaged cutting edge. To solve these concerns, this paper presents a new mechanistic model of cutting forces based on tool motion analysis. In the model, for undeformed chip thickness determination, an analytical model is first established to describe the sweep surface of cutting edge during the five-axis ball-end milling process of curved geometries. The undeformed chip thickness is then calculated according to the real kinematic trajectory of cutting edges under continuous change of the cutter axis orientation. A Z-map method is used to verify the engaged cutting edge and cutting coefficients are subsequently calibrated. The mechanistic method is applied to predict the cutting force. Validation tests are conducted under different cutter postures and cutting conditions. The comparison between predicted and measured values demonstrates the applicability of the proposed prediction model of cutting forces.

Modeling of Ball-End Milling Forces With Cutter Axis Inclination

1999 ◽  
Vol 122 (1) ◽  
pp. 3-11 ◽  
Author(s):  
Ismail Lazoglu ◽  
Steven Y. Liang
Keyword(s):  
End Milling ◽  
Chip Thickness ◽  
Helix Angle ◽  
Force Model ◽  
Ball End Mill ◽  
Ball End Milling ◽  
Model Predictions ◽  
Milling Forces ◽  
Analytical Force Model ◽  
Convolution Method

In the machining of sculpture surfaces with ball-end mill, the cutter axis or workpiece is often inclined to generate an admissible orientation. This paper primarily presents an enhanced cutting force model for ball-end milling with cutter axis inclination. It involves the kinematic reasoning of cutting edge geometry, local helix angle and average chip thickness followed by the analysis of effects of axis inclination in the contact zone between cutter and workpiece. Thereupon, development of the analytical force model for inclined-axis machining is achieved using cutter angle domain convolution method. Experimental evaluation of the model is discussed, and experimental results and model predictions under various cutting conditions are compared in the frequency as well as in the angular domain. [S1087-1357(00)70601-0]

Estimation of in-process cutting constants in ball-end milling

2003 ◽  
Vol 217 (1) ◽  
pp. 45-56 ◽  
Author(s):  
C M Zheng ◽  
J -J Junz Wang
Keyword(s):  
Cutting Forces ◽  
End Milling ◽  
Estimation Methods ◽  
Force Model ◽  
Average Force ◽  
Ball End Milling ◽  
Source Signal ◽  
Matrix Expression ◽  
Milling Forces ◽  
Milling Force Model

Two methods are presented for the estimation of tangential, radial and axial cutting coefficients for the shearing and ploughing mechanisms from a single set of cutting forces in ball-end milling. These estimation methods are based upon the invertibility of the analytical milling force model, which considers both the shearing and the ploughing mechanisms by incorporating their respective cutting constants in the local force model. The periodic milling forces are established as the convolution integral of the differential local cutting forces and their Fourier coefficients are derived and expressed in a matrix expression as a linear function of the unknown cutting constants in terms of cutting conditions and cutter geometry. This linear expression thus leads to a systematic formulation of the estimation methods allowing the six unknown cutting constants to be determined from the measured milling forces. The first method uses the first harmonic forces as the source signal while the second method extracts the six cutting constants from the average force as well as the first harmonics. Limitations of both estimation methods are discussed. The consistency and accuracy of the estimated cutting constants are confirmed by the experimental results.

Cutting Force Simulation in Minute Time Resolution for Ball End Milling Under Various Tool Posture

2017 ◽  
Vol 140 (2) ◽  
Author(s):  
Isamu Nishida ◽  
Ryuma Okumura ◽  
Ryuta Sato ◽  
Keiichi Shirase
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Chip Thickness ◽  
Cutting Edge ◽  
New Method ◽  
Uncut Chip Thickness ◽  
Tool Posture ◽  
Voxel Model ◽  
Five Axis ◽  
Milling Forces

A new cutting force simulator has been developed to predict cutting force in ball end milling. In this simulator, uncut chip thickness is discretely calculated based on fully voxel models representing both cutting edge and instantaneous workpiece shape. In the previous simulator, a workpiece voxel model was used to calculate uncut chip thickness under a complex change of workpiece shape. Using a workpiece voxel model, uncut chip thickness is detected by extracting the voxels removed per cutting tooth for the amount of material fed into the cutting edge. However, it is difficult to define the complicated shape of cutting edge, because the shape of cutting edge must be defined by mathematical expression. It is also difficult to model the voxels removed by the cutting edge when tool posture is nonuniformly changed. Therefore, a new method to detect uncut chip thickness is proposed, one in which both cutting edge and instantaneous workpiece shape are fully represented by a voxel model. Our new method precisely detects uncut chip thickness at minute tool rotation angles, making it possible to detect the uncut chip thickness between the complex surface shape of the workpiece and the particular shape of the cutting edge. To validate the effectiveness of our new method, experimental five-axis milling tests using ball end mill were conducted. Estimated milling forces for several tool postures were found to be in good agreement with the measured milling forces. Results from the experimental five-axis milling validate the effectiveness of our new method.

Cutting Force Model for Contour Surface Machining of Gear Indexing Cam with Flat End Milling

2004 ◽  
Vol 471-472 ◽  
pp. 122-126 ◽  
Author(s):  
P.Q. Guo ◽  
Chuan Zhen Huang ◽  
Ping Zhao
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Depth Of Cut ◽  
Force Model ◽  
Uncut Chip Thickness ◽  
Thickness Change ◽  
Flat End Milling ◽  
Axial Depth

This paper presents a model to predict the cutting forces for flat end milling as machining gear indexing cam. Rotation feeding makes axial depth of cut and uncut chip thickness change during cutting process. The development of the model is based on the analysis of cutting edge expression. According to the existing the relationship of the local cutting force and chip load and assuming the cutter to be divided into a number of differential elements in the axial direction of the cutter, the model is derived by summarising the cutting forces produced by each differential cutter disc engaged in the cut. The equation for calculating uncut chip thickness of differential disc is educed. In order to avoid the complex computing for axial depth of cut of the entire edge, a unit square window function and its criterion are introduced to estimate whether a segment of edge is in engaging range.

A wavelet approach to predict surface roughness in ball-end milling

2015 ◽  
Vol 231 (14) ◽  
pp. 2468-2478 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Prae Thesniyom ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Wavelet Transform ◽  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Detection System ◽  
Milling Process ◽  
Cutting Conditions ◽  
Ball End Milling ◽  
Dynamic Cutting Force

This research proposed an advance in the prediction of the in-process surface roughness during the ball-end milling process by utilizing the wavelet transform to monitor and decompose the dynamic cutting forces. The chatter detection system has been adopted from the previous research of the author to avoid the chatter first, and hence, the dynamic cutting force ratio is introduced to predict the in-process surface roughness during the normal cutting by taking the ratio of the decomposed dynamic cutting force in X axis to that in Z axis. The Daubechies wavelet transform is employed in this research to analyze the in-process surface roughness. The experimentally obtained results showed that the surface roughness frequency occurred at the same level of the decomposed dynamic cutting forces although the cutting conditions are changed. It is understood that the in-process surface roughness can be predicted effectively under various cutting conditions referring to the proposed monitoring system.

Ball-End Milling of Cr12MoV Die Steel Using Ceramic Tool and Cements Carbide Tool

2012 ◽  
Vol 565 ◽  
pp. 466-471
Author(s):  
Bin Zou ◽  
Chuan Zhen Huang ◽  
Zi Ye Liu ◽  
Xin Qiang Zhuang ◽  
Jun Wang
Keyword(s):  
Cutting Forces ◽  
End Milling ◽  
Cutting Tools ◽  
Cutting Conditions ◽  
Cemented Carbide ◽  
Cutting Condition ◽  
Die Steel ◽  
Ball End Milling ◽  
Carbide Insert ◽  
Ceramic Insert

Ball-end milling of Cr12MoV die steel was studied using ceramic and cemented carbide inserts under different cutting conditions. The cutting forces, wear patterns and chip patterns generated using the different cutting tools at the different cutting conditions were investigated using a three component piezoelectric dynamometer and VHX-600E large depth-of-view 3-D scanner. The relationships among the cutting forces, wear patterns and chip patterns were discussed. The results indicated that the cutting forces caused by the ceramic insert were slightly lower than those caused by the cemented carbide insert under the same cutting conditions. For ceramic inserts, effects of cutting conditions on the rake face wear were different from those on the flank wear. The higher wear for the ceramic insert was caused at the lower cutting conditions but the higher wear for the cemented carbide insert was encountered at the higher cutting conditions. The squeezed chip was involved with the higher cutting forces. The sharper cutting edge of the cemented carbide insert was responsible for chip patterns caused by the No. I cutting condition. The effects of cutting conditions on wear patterns were more evident than that on chip patterns.

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