A novel mathematical model for grinding ball-end milling cutter with equal rake and clearance angle

Chen, Fengjun; Hu, Sijie; Yin, Shu

doi:10.1007/s00170-011-3889-y

Cited by 25 publications

(7 citation statements)

References 16 publications

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“…Our purpose here is to establish novel mathematical modeling for proposing the tool for manufacturing the globoidal cam. Mathematical modeling methods of tools have been studied in the extant literature, such as milling tool [23][24][25][26], turning tool [27], skiving tool [28], worm-shaped tool [29], barrel-shaped tool [30], form-cutting tool [31] and others [32][33][34][35][36]. A mathematical modeling method of the whirl-machining tool has recently been utilized to simulate double enveloping worms manufacturing [37].…”

Section: Introductionmentioning

confidence: 99%

Mathematical modeling on a novel manufacturing method for roller-gear cams using a whirl-machining process

Andrianto

Wu²,

Arifin³

2023

Int J Adv Manuf Technol

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The whirl-machining process is a precise, efficient, and promising machine process for manufacturing workpieces over the milling process. At the same time, the roller-gear cam has advantages over the other camfollower system. However, the whirl-machining process has not been applied to manufacture the roller-gear cam. Therefore, this paper proposes a novel method for roller-gear cam manufacturing using a whirl-machining process. Mathematical modeling is described for generating the roller-gear cam, roller, and whirl-milling tool surface. A novel CNC machine and its coordinate system are proposed. Cutting simulations for obtaining the surface topologies and normal deviations are conducted. Globoidal cam with different cylindrical rollers, globoidal cam with a conical roller, and cylindrical cam with a conical roller are taken as case studies, and results are discussed. A virtual cutting simulation was conducted using VERICUT. Some machining examples are shown to verify the benefits of the proposed method in roller-gear cam manufacturing.

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Section: Introductionmentioning

confidence: 99%

Mathematical modeling on a novel manufacturing method for roller-gear cams using a whirl-machining process

Andrianto

Wu²,

Arifin³

2023

Int J Adv Manuf Technol

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“…Wang et al [10] generated a model of grinding wheel trajectory for machining helical grooves in terms of the grinding wheel's position and orientation, and provided a new approach for flute grinding of end milling cutters. Chen et al [11] proposed new mathematical models and grinding methods of BEMC based on the orthogonal spiral cutting edge curve. It was found through the grinding experiments that both rake face with equal rake angle and flank face with equal clearance angle improved effectively chip removal conditions and machining performance of BEMC.…”

Section: Introductionmentioning

confidence: 99%

Study on design, manufacture, and cutting performance of circular-arc milling cutters for machining titanium alloy

Chen

Liu

Yujiang

et al. 2021

Int J Adv Manuf Technol

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Titanium alloy is widely used for manufacturing structural parts of high-end equipment due to its excellent mechanical properties, despite difficulty in being machined. Nowadays, titanium alloy parts are mostly machined by ball-end milling cutters (BEMC), but the cutting edge structure of the BEMC limits the improvement in machining efficiency and surface quality of the parts. In this paper, a circular-arc milling cutter (CAMC) with large-curvature cutting edge was proposed; the differential geometry method was used for establishing the geometric model for the contour surface of the CAMC and the mathematical model for the spiral cutting edge line; the conversion matrix between grinding wheel and workpiece coordinates was introduced to derive the equation of grinding wheel trajectory when the rake face of the CAMC was ground; the self-designed CAMC was ground and tested in accuracy. The comparative research was conducted experimentally on the side milling of titanium alloy TC4 with the CAMC and BEMC, and consequently the variation laws of milling forces, wear morphology and machined surface quality were obtained about the two types of milling cutters. The results indicated that the CAMC can effectively reduce the main milling force and keep the milling process stable. Moreover, the CAMC was worn slower and produced better surface quality than the BEMC.

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“…These scholars have done a great deal of excellent work in the design and manufacturing of new cutting tools. The existing research focuses on helical edge design, geometric angle optimization and grinding manufacturing of ball-end milling cutters [14][15][16][17][18][19]. Ball-end milling cutters have been widely used in the field of machining, and because of the limitation of processing equipment and grinding method, there has been little research on new cutting tools for titanium alloy processing.…”

Section: Introductionmentioning

confidence: 99%

Study on the Design and Cutting Performance of a Revolving Cycloid Milling Cutter

Wang¹,

Liu²,

Gao³

et al. 2019

Applied Sciences

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Problems such as low machining efficiency, severe tool wear and difficulty in safeguarding surface quality always exist in the machining process of titanium alloy with ball-end milling cutters. To address these issues, the design and manufacture of a revolving cycloid milling cutter for titanium alloy processing were studied in this paper. Firstly, the mathematical model of the revolving cycloid milling cutter contour surface was established. The parametric equation of an orthogonal helix cutting edge curve of a revolving cycloid milling cutter is presented. Then, the bottom boundary curve of the rake face is introduced. The five-axis grinding trajectory equation of revolving cycloid milling cutter rake face was derived based on the edge curve equation and coordinate transformation. Next, fabricating the revolving cycloid milling cutter and detecting the grinding accuracy of tool profile and geometric angle were performed. At last, a contrast test regarding the performance of the revolving cycloid milling cutter and the ball-end milling cutter in cutting titanium alloy TC11 was carried out. According to the test results, in comparison to the ball-end milling cutter, the revolving cycloid milling cutter had a smaller ratio of the axial force to the tangential force. Moreover, its flank face wore more slowly and evenly. As a result, a good surface processing quality can be maintained even under larger wear conditions, demonstrating an outstanding cutting performance.

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A novel mathematical model for grinding ball-end milling cutter with equal rake and clearance angle

Cited by 25 publications

References 16 publications

Mathematical modeling on a novel manufacturing method for roller-gear cams using a whirl-machining process

Mathematical modeling on a novel manufacturing method for roller-gear cams using a whirl-machining process

Study on design, manufacture, and cutting performance of circular-arc milling cutters for machining titanium alloy

Study on the Design and Cutting Performance of a Revolving Cycloid Milling Cutter

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