Analysis of Cutting Mechanism by Ball End Mill Using 3D-CAD (Chip Area by Inclined Surface Machining and Cutting Performance Based on Evaluation Value)

Abstract

This paper deals with an analysis of the chip area by ball end milling of an inclined surface using a contour path method. At first, the modeling of a cutter, an edge, a rake surface and a workpiece with an inclined surface are carried out using 3D-CAD. Secondly, the chip area is calculated by the interference of the rake surface and the chip volume. The influence of the cutting method and the direction of pick feed on the behavior of the chip area and the influence of the inclination angle of the machined surface on the maximum chip area are shown. And, the evaluation value E d for cutting performance with the multiple by the chip area and the distance from the spindle axis to the center of gravity of the chip area is proposed. The evaluation value of the condition by stepping up pick feed and the inclination angle α = 20• shows minimum, so a good cutting performance would be expected for these cutting conditions.

C030 Study on Evaluation of Cutting Performance of Ball End Mill with Straight-line Path Method for Inclined Surface Using 3D-CAD : Influence of Feed Direction on Cutting Mechanism

“…The theoretical roughness R th of the finished surface by ball end milling in the pick feed direction is given in Equation (3).…”

“…Therefore, the purpose of this study is to propose a highly efficient and accurate cutting method using a 5-axis control machine tool. First, a cutting model assembled by a ball end mill and a workpiece with an inclined surface is carried out with 3D-CAD (SolidWorks) by using a similar method as reported previously [3,4]. Next, the cross-sectional cutting area A is calculated by the interference of the rake surface of the tool and the uncut chip volume which can be removed by one cutting operation.…”

Study on Cutting Mechanism and Cutting Performance of Machining for Curved Surface by Ball End Mill using 3D-CAD

“…Figure 4 shows the result by the measurement and the estimated shape calculated by the equation (22) . From Fig.4, the both cutting edge shape are almost coincident and the error of cutter rotation angle δc at each edge point is less than ±3.7°.…”

“…In spite of the difficult cutting mechanism with a ball end mill, many papers have been produced and they are grouped as follows. (1) cutting force measurement and prediction (3)～(6) , (2) generation of machined surface (7)～ (10) , (3) cutting performance by a special tools (11)～ (13) , (4) regenerative cutter vibration (14) , (5) tool life and machining accuracy (15)～ (17) , (6) fabrication of tools and cutting characteristics (18) (19) , (7) surface roughness and optimum cutting condition (20) (21) and (8) chip area and evaluation value (22) . The above studies provide much useful knowledge, but chip area during cutting is not accurately clear.…”

Study on Cutting Mechanism and Cutting Performance of Machining for Curved Surface by Ball End Mill using ３D－CAD

“…The cutting edge shape projected on the X-Y plane of the end part of a ball end mill available on the market is measured by the digital microscope (Keyence VH-6300). Figure 4 shows the result by the measurement and the estimated shape calculated by the equation (22) . From Fig.…”