scholarly journals A Prediction Model of Cutting Force about Ball End Milling for Sculptured Surface

2020 ◽  
Vol 2020 ◽  
pp. 1-15
Author(s):  
Wenping Mou ◽  
Shaowei Zhu ◽  
Menghao Zhu ◽  
Lei Han ◽  
Lei Jiang
Keyword(s):  
Prediction Model ◽  
Coordinate System ◽  
Cutting Force ◽  
Sculptured Surface ◽  
Machining Parameters ◽  
End Mill ◽  
Ball End Mill ◽  
Surface Machining ◽  
Sculptured Surface Machining ◽  
Tool Posture

Cutting force prediction is very important to optimize machining parameters and monitor machining state. In order to predict cutting force of sculptured surface machining with ball end mill accurately, tool posture, cutting edge, contact state between cutter, and workpiece are studied. Firstly, an instantaneous motion model of ball end mill for sculptured surface is established. The instantaneous milling coordinate system and instantaneous tool coordinate system are defined to describe the position and orientation of tool, and the transformation matrix between coordinate systems is derived. Secondly, by solving three boundaries around engagement of cutter and workpiece, a cutter-workpiece engagement model related to tool posture, milling parameters, and tool path is established. It has good adaptability to the variable tool axis relative to the machining surface. Finally, an algorithm of thickness about an instantaneous undeformed chip is researched, and a prediction model of cutting force is realized with microelement cutting theory. Also, the model is suitable for sculptured surface machining with arbitrary tool posture and feed direction. The accuracy of the proposed prediction model was verified by a series of experiments.

Milling Force Prediction Model for Five-Axis Machining of Freeform Surface Considering Mesoscopic Size Effect

2021 ◽  
Vol 143 (9) ◽  
Author(s):  
Minglong Guo ◽  
Zhaocheng Wei ◽  
Minjie Wang ◽  
Jia Wang ◽  
Shengxian Liu
Keyword(s):  
Dislocation Density ◽  
Size Effect ◽  
Prediction Model ◽  
Cutting Force ◽  
Freeform Surface ◽  
End Mill ◽  
Ball End Mill ◽  
Milling Force ◽  
Force Prediction ◽  
Five Axis

Abstract The core parts with the characteristic of freeform surface are widely used in the major equipment of various fields. Cutting force is the most important physical quantity in the five-axis CNC machining process of core parts. Not only in micro-milling, but also in macro-milling, there is also an obvious size effect, especially in medium- and high-speed milling, which is frequently ignored. In this paper, the milling force prediction model for five-axis machining of a freeform surface with a ball-end mill considering the mesoscopic size effect is established. Based on the characteristics of cutting thickness in macro-milling, a new dislocation density correction form is proposed, and a new experiment is designed to identify the dislocation density correction coefficient. Therefore, the shear stress calculated in this paper not only reflects the cutting dynamic mechanical characteristics but also considers the mesoscopic size effect. A linear function is proposed to describe the relationship between friction coefficient and cutting speed, cutter rake angle, and cutting thickness. Considering cutter run-out, the micro-element cutting force in the shear zone and plough zone are analyzed. The cutting geometry contact between the freeform surface and the ball-end mill is analyzed analytically by the space limitation method. Finally, the total milling force is obtained by summing all the force vectors of cutting edge micro-elements within the in-cut cutting edge. In the five-axis machining experiment of freeform surface, the theoretically predicted results of milling forces are in good agreement with the measured results in trend and amplitude.

Prediction of cutting force for ball end mill in sculptured surface based on analytic model of CWE and ICCE

2019 ◽  
Vol 23 (5) ◽  
pp. 688-711 ◽  
Author(s):  
Z. C. Wei ◽  
M. L. Guo ◽  
M. J. Wang ◽  
S. Q. Li ◽  
J. Wang
Keyword(s):  
Cutting Force ◽  
Sculptured Surface ◽  
Analytic Model ◽  
End Mill ◽  
Ball End Mill

Tool Path Generation for Five-Axis Controlled Machining of Free-Form Surface Using Barrel Tool: Control of Contact Point on Cutting Edge

2020 ◽  
Author(s):  
Tomonobu Suzuki ◽  
Koichi Morishige
Keyword(s):  
Tool Path ◽  
Contact Point ◽  
Cutting Edge ◽  
Free Form ◽  
End Mill ◽  
Ball End Mill ◽  
Surface Machining ◽  
Free Form Surface ◽  
The Cost ◽  
Five Axis

Abstract This study aimed to improve the efficiency of free-form surface machining by using a five-axis controlled machine tool and a barrel tool. The barrel tool has cutting edges, with curvature smaller than the radius, increasing the pick feed width compared with a conventional ball end mill of the same tool radius. As a result, the machining efficiency can be improved; however, the cost of the barrel tool is high and difficult to reground. In this study, a method to obtain the cutting points that make the cusp height below the target value is proposed. Moreover, a method to improve the tool life by continuously and uniformly changing the contact point on the cutting edge is proposed. The usefulness of the developed method is confirmed through machining simulations.

Automatic Planning for 5-Axis Sculptured Surface Machining

1994 ◽  
Author(s):  
Yuan-Shin Lee ◽  
Tien-Chien Chang
Keyword(s):  
Sculptured Surface ◽  
Sculptured Surfaces ◽  
Design Modification ◽  
Surface Machining ◽  
Sculptured Surface Machining ◽  
Cutter Path ◽  
Automatic Planning ◽  
Five Axis ◽  
Five Axes ◽  
Complete Operation

Abstract In modern product design, sculptured surfaces are commonly used for functional and artistic shape design. Design of sculptured surfaces is evolutionary, consisting primarily of incremental changes to existing part surfaces. Manual operation planning for sculptured surface machining is known to be error-prone and inefficient, which requires considerable checking, verification, and rework. Five-axis machining has higher productivity and better machining quality than 3-axis machining. However, the programming for 5-axis machining is more difficult due to the complex simultaneous cutter movements along the machine’s five axes. This paper presents a systematic methodology to generate operation plans for 5-axis sculptured surface machining. A complete operation plan and the error-free cutter path can be automatically generated from the CAD part design. To achieve design for manufacturing of sculptured surface products, the machining unfeasibility information can be fed back to the designer for further design modification. Results of computer implementation and testing examples are also presented.

Interactive and Collaborative Virus-Evolutionary CNC Machining Optimization Environment

2015 ◽  
pp. 110-141
Author(s):  
N. A. Fountas ◽  
N. M. Vaxevanidis ◽  
C. I. Stergiou ◽  
R. Benhadj-Djilali
Keyword(s):  
Cnc Machining ◽  
Machining Parameters ◽  
Sculptured Surfaces ◽  
Surface Machining ◽  
Theory Of Evolution ◽  
Sculptured Surface Machining ◽  
Novel Approach ◽  
Manufacturing Software ◽  
Machining Strategies ◽  
Machining Optimization

Research on the area of sculptured surface machining optimization is currently directed towards the implementation of artificial intelligence techniques. This chapter aims at presenting a novel approach of optimizing machining strategies applied to manufacture complex part geometries. Towards this direction a new genetic-evolutionary algorithm based on the virus theory of evolution is developed as a hosted module to a commercial and widely known CAM system. The new genetic algorithm automatically evaluates pairs of candidate solutions among machining parameters for roughing and finishing operations so as to optimize their values for obtaining optimum machining programs for sculptured parts in terms of productivity and quality. This is achieved by introducing new directions of manipulating manufacturing software tools through programming and customization. The environment was tested for its efficiency and has been proven capable of providing applicable results for the machining of sculptured surfaces.

Voxel Based Cutting Force Simulation of Ball End Milling Considering Cutting Edge Around Center Web

2018 ◽  
Author(s):  
Isamu Nishida ◽  
Takaya Nakamura ◽  
Ryuta Sato ◽  
Keiichi Shirase
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Chip Thickness ◽  
Previous Method ◽  
Cutting Edge ◽  
Force Model ◽  
End Mill ◽  
Uncut Chip Thickness ◽  
Ball End Mill ◽  
Tool Rotation

A new method, which accurately predicts cutting force in ball end milling considering cutting edge around center web, has been proposed. The new method accurately calculates the uncut chip thickness, which is required to estimate the cutting force by the instantaneous rigid force model. In the instantaneous rigid force model, the uncut chip thickness is generally calculated on the cutting edge in each minute disk element piled up along the tool axis. However, the orientation of tool cutting edge of ball end mill is different from that of square end mill. Therefore, for the ball end mill, the uncut chip thickness cannot be calculated accurately in the minute disk element, especially around the center web. Then, this study proposes a method to calculate the uncut chip thickness along the vector connecting the center of the ball and the cutting edge. The proposed method can reduce the estimation error of the uncut chip thickness especially around the center web compared with the previous method. Our study also realizes to calculate the uncut chip thickness discretely by using voxel model and detecting the removal voxels in each minute tool rotation angle, in which the relative relationship between a cutting edge and a workpiece, which changes dynamically during tool rotation. A cutting experiment with the ball end mill was conducted in order to validate the proposed method. The results showed that the error between the measured and predicted cutting forces can be reduced by the proposed method compared with the previous method.

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