Analysis of Surface Roughness Generation by Ball Endmill Machining.

Koreta, Noriyuki; Egawa, Tsuneo; Kuroda, Motofumi; Watanabe, K.; Yoshiharu,

doi:10.2493/jjspe.59.1537

Cited by 26 publications

(8 citation statements)

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“…It has also been found that the conventional roughness model is inappropriate for the evaluation of surface roughness under a high-efficiency machining condition. In previous research [21], the cutting simulation was performed with consideration of the actual trochoid paths of cutting edges based on the disk-tool approximation model, and it has been observed that the height of the cut remainder formed in the vicinity of the rotational centre of the tool is generally larger than the conventional cusp height.…”

Section: Disk-tool Approximation Modelmentioning

confidence: 99%

“…Kim and Chu [19,20] studied the effects of cutter marks and run-out and predicted the machined surface texture by the superposition of the cutter marks and the conventional scallop surface. For a more exact prediction of the geometrical machining error, Koreta and Egawa [21] investigated the topologies of machined surfaces for highly efficient cutting conditions by simulating the envelopes of the cutting edges employing the conventional Z-map method. It has been noted in their work that the surface roughness for high-efficiency machining conditions cannot be evaluated by the conventional roughness model.…”

Section: Introductionmentioning

confidence: 99%

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A new approach to analysing machined surfaces by ball-end milling, part I:

Jung

Yang

Lee

2004

Int J Adv Manuf Technol

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Since productivity and product quality are always regarded as important issues in manufacturing technologies, a reliable method for predicting machining errors is essential to meeting these two conflicting requirements. However, the conventional roughness model is not suitable for the evaluation of machining errors for highly efficient machining conditions. Therefore, a different approach is needed for a more accurate calculation of machining errors. This study deals with the geometrical surface roughness in ball-end milling. In this work, a new method, called the ridge method, is proposed for the prediction of the machined surface roughness in the ball-end milling process. In Part I of this two-part paper, a theoretical analysis for the prediction of the characteristic lines of the cut remainder are generated from a surface generation mechanism of a ballend milling process, and three types of ridges are defined. The trochoidal trajectories of cutting edges are considered in the evaluation of the cut remainder. The predicted results are compared with the results of a conventional roughness model.

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Section: Disk-tool Approximation Modelmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A new approach to analysing machined surfaces by ball-end milling, part I:

Jung

Yang

Lee

2004

Int J Adv Manuf Technol

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“…However, highspeed machining requires a small removal volume and a high feedrate. The effect of the cutter mark in the feed direction should no longer be negligible [11][12][13][14]. Therefore, the control of the cutter mark height in the feed direction insures surface quality of high feed machining and saves time in manual postprocessing.…”

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confidence: 99%

Curve interpolation with variable feedrate for surface requirement

Choi

Yang

Hong

et al. 2004

Int J Adv Manuf Technol

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Finish machining of a curved surface is often carried out by an NC system with curve interpolation in the field. This function, called a NURBS interpolation, adopts a feedrate optimizing strategy based on both the geometrical information of the curved path and dynamic properties such as the curvature of the curve, the allowable acceleration and the time constant. However, in the case of a finish cut using a ball-end mill, the curve interpolator needs to take the machining process into account for improved surface roughness, while reducing the polishing time. This surface roughness on high-speed machining is theoretically defined by the feed per tooth and the pickfeed at the given radius of the tool. In this study, the effect of low machinability at the bottom of a tool on surface roughness is also considered. A curve interpolation algorithm is proposed for generating particular feedrate commands that are able to control the roughness of a curved surface. The simulation of the machined surface by the proposed algorithm was carried out, and experimental results are presented. A feedrate scheme that depends on the inclination angle has important potential application in part finishes consistent with prescribed surface roughness. The results show that the proposed algorithm is potentially useful for roughness-controlled machining of curved surface products.

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“…Hirogaki et al (13) observed finish surfaces machined by 5-axis ball end milling and reported a similar finding; that is, they obtained preferable surface features by keeping the inclination angle of a cutting tool constant. In the analytical approach, Koreta et al (14) theoretically made a geometrical model to analyze surface roughness. Their analysis showed that the cut remainder increased with increasing feed rate.…”

Section: Introductionmentioning

confidence: 99%

Establishing a Novel Model for 5-Axis Milling with a Filleted End Mill

Sekine

Obikawa

Hoshino

2012

JAMDSM

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This paper focuses on the mathematical modeling for 5-axis milling with a filleted end mill. Several coordinate systems are introduced to describe the relationship between a cutter orientation and a machined surface. Then, a cutting point on a cutting edge is geometrically formulated as an integrated form of some expressions. The fundamental simulations based on the modeling were implemented to investigate the characteristics of path-interval and feed-interval scallops on a machined surface; moreover, path interval determination is proposed for suitable estimation in filleted end milling. As a result, it was found that the proposed approach could provide the characteristics of microscopic topography in detail.

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Analysis of Surface Roughness Generation by Ball Endmill Machining.

Cited by 26 publications

References 0 publications

A new approach to analysing machined surfaces by ball-end milling, part I:

A new approach to analysing machined surfaces by ball-end milling, part I:

Curve interpolation with variable feedrate for surface requirement

Establishing a Novel Model for 5-Axis Milling with a Filleted End Mill

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