The Prediction of Surface Accuracy in End Milling

1982 ◽  
Vol 104 (3) ◽  
pp. 272-278 ◽  
Author(s):  
W. A. Kline ◽  
R. E. DeVor ◽  
I. A. Shareef
Keyword(s):  
Optimization Problems ◽  
End Milling ◽  
Milling Process ◽  
Force System ◽  
Surface Error ◽  
Design And Optimization ◽  
Surface Errors ◽  
Cutter Deflection ◽  
The Difference ◽  
End Milling Process

In the end milling process, the cutting forces during machining produce deflection of the cutter and workpiece which result in dimensional inaccuracies or surface error on the finished component. A previously developed mathematical model for the cutting force system in end milling is combined with models for cutter deflection and workpiece deflection so that the surface error profile may be predicted from the machining conditions and geometry and material properties of the cutter and workpiece. Machining experiments are performed on rigid and flexible workpieces of 7075 aluminum to verify the ability of the models to predict surface error. The model predicted surface error profiles are accurate both in magnitude and shape with the difference between measured and predicted surface errors ranging from 5 to 15 percent. This approach for the prediction of surface errors provides a useful aid for the analysis of a variety of end milling process design and optimization problems.

Generalized Mechanistic Force System Model of Ball-End Milling for Sculpture Surface Machining

2001 ◽  
Author(s):  
Ismail Lazoglu
Keyword(s):  
End Milling ◽  
Mechanistic Model ◽  
Milling Process ◽  
Force System ◽  
Workpiece Surface ◽  
Surface Machining ◽  
Ball End Milling ◽  
End Milling Process ◽  
Validation Experiments ◽  
Good Agreement

Abstract In this paper, a new mechanistic model is developed for the prediction of cutting force system in ball-end milling process. The key feature of the model includes the ability to calculate the workpiece / cutter intersection domain automatically for a given cutter location (CL) file, cutter and workpiece geometries. Moreover, an analytical approach is used to determine the instantaneous chip load and cutting forces. The model also employs a Boolean approach for given cutter, workpiece geometries, and the CL file in order to determine the surface topography and scallop height variations along the workpiece surface which can be visualized in 3-D. Some of the typical results from the model validation experiments performed on Ti-6A1-4V are also reported in the paper. Comparisons of the predicted and measured forces as well as the surface topographies show good agreement.

Modeling and Simulation of Surface Texture for End-Milling Process

2017 ◽  
pp. 19-39
Author(s):  
Manoj Kumar
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Milling Process ◽  
Simulation Software ◽  
Computational Algorithms ◽  
Roughness Parameters ◽  
Surface Errors ◽  
Surface Location ◽  
Computer Resources ◽  
End Milling Process

Analysis and simulation of manufacturing process require extensive and complicated computations. Nowadays, computer resources and computational algorithms reach to the state that can model and simulate the problem efficiently. One of the important processes in manufacturing is machining. In this research end-milling process which is one of the complex and wide-spread processes in machining is chosen. Most important parameters in end-milling are surface roughness and surface location errors. A comprehensive simulation software is developed to model end-milling process in order to anticipate finishing parameter such as surface roughness and errors. The proposed algorithm takes into account cutting conditions, such as feed, doc, woc, tool run out, etc. In addition, dynamic simulation module of the software can accurately model flexible end-mill tool, the milling cutting forces and regeneration of waviness effects. The software can accurately determine the most commonly used index of surface roughness parameters such as Ra, P.T.V. and surface errors.

Research on the Influence Factors for the Deflection of Micro-Ball-End Cutter in Micro-End-Milling Process

2011 ◽  
Vol 697-698 ◽  
pp. 84-87 ◽  
Author(s):  
Ming Jun Chen ◽  
Zhi Jun Wang ◽  
Chun Ya Wu ◽  
Hai Bo Ni
Keyword(s):  
End Milling ◽  
Three Dimensional ◽  
Great Influence ◽  
Milling Process ◽  
Micro Milling ◽  
Machining Parameters ◽  
Cutting Depth ◽  
Cutter Deflection ◽  
Micro End Milling ◽  
End Milling Process

Machining parameters and spindle radial runout have great influence on the micro-ball-end cutter deflection in the micro-end-milling process. In this study, a 3D (three-dimensional) thermal-mechanical FEM (finite element method) model of micro-milling with non-rigid cutter is built to study how radial runout, cutting depth, feed and spindle speed influence the cutter deflection when feed has the same direction with the spindle radial runout. Cutter deflection under different groove lengths, cutting depths, feeds and spindle speeds is investigated, which shows that cutter deflection increases with spindle radial runout significantly. The largest deflections with runout of 2μm are 3.26μm, 3.26μm, 4.71μm and 4.52μm respectively under the adopted machining conditions, while the largest deflections without runout are 1.85μm, 1.85μm, 2.26μm and 3.79μm respectively. It is also shown that the runout effect increases with groove length, cutting depth, while it decreases with feed.

TOPSIS based selection of optimal end milling process parameters

2020 ◽  
Author(s):  
A. Singh ◽  
I. Shivakoti ◽  
Z. Mustafa ◽  
R. Phipon ◽  
A. Sharma
Keyword(s):  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
End Milling Process ◽  
Selection Of

Machining feasibility and sustainability study on end milling process of Monel alloy

2021 ◽  
Author(s):  
Muhammed Shihan ◽  
J. Chandradass ◽  
T.T.M. Kannan ◽  
S.M. Sivagami
Keyword(s):  
End Milling ◽  
Milling Process ◽  
End Milling Process
Sign in / Sign up

Export Citation Format

Share Document