Cutting force prediction of sculptured surface ball-end milling using Z-map

Kim, G.M.; Cho, P.J.; Chu, Chong Nam

doi:10.1016/s0890-6955(99)00040-1

Cited by 154 publications

(79 citation statements)

References 10 publications

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“…The model parameters constants a 0 ,a 1 ,a 2 ,a 3 and b 0 ,b 1 ,b 2 ,b 3 in Equation 7 were obtained using the least squares technique from Equation (8) and Equation (9). And the specific cutting pressures were given as: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 In the ball-end milling applications, where the tests-piece is P20 (AISI), the cutting forces on the cutter can be calculated using Equations 6, 12 and 13.…”

Section: Calibration Of a Cutting Force Model For Milling P20 Steelmentioning

confidence: 99%

The influence of cutting force on surface machining quality

Fan

Loftus

2007

International Journal of Production Research

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Section: Calibration Of a Cutting Force Model For Milling P20 Steelmentioning

confidence: 99%

The influence of cutting force on surface machining quality

Fan

Loftus

2007

International Journal of Production Research

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“…Later, they studied the maximum values of three cutting force components considering inclination angle to determine the favorable tool orientation and limit the deflection for the certain cutter [19]. Attention was also given to the analysis of the undeformed chip geometry and cutter-workpiece contact area using -map data for ball end mill by Kim et al [20]. Meanwhile, Cao et al proposed a new experimental method to identify the force coefficients including the inclination angle in finish milling for ball-end mill, and it was superior to the slot experimental method [21].…”

Section: Advances In Mechanical Engineeringmentioning

confidence: 99%

Prediction and Experimental Validation of Cutting Force for Bull-Nose End Mills with Lead Angle

Gao

Luo

et al. 2014

Advances in Mechanical Engineering

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This study focuses on cutting force predictions with the tool-workpiece inclination angle in bull-nose milling based on the semimechanistic force model. By analyzing kinematics and mechanics of the bull-nose end mills during cutting, force expressions including lead angle are stated and the model is exerted on each discrete element as oblique cutting with coordinate transformation and numerical integration to obtain the dynamic cutting force components. An improved identification method considering speed variations along the tool axis is applied to calibrate coefficients. Coefficients are regarded as the function of each elemental elevation. Then, a geometry-based method to acquire cutter workpiece engagement (CWE) is proposed. Also acquisition of accurate start and exit angles on each slice is deliberated elaborately for cutters with lead or tilt angle in milling processes. Thereby, to verify the validity of the force prediction model and start-exit angle acquisition method, experiments with variable lead angles are conducted under different axial immersions. The results reveal that the presented model and approaches can predict cutting forces with high accuracy. Finally, the cutting force components under different cutter postures and conditions are analyzed to provide instructions for parameter selections.

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“…Nonetheless, these two directions, as originally proposed for horizontal cuts, may not characterize non-horizontal and rotational cuts correctly. Notably, Kim et al [32] introduced a different concept and proposed to use the cutter feed direction to determine the undeformed chip thickness for non-horizontal cuts. As for the much more complex rotational ball-end milling cuts (due to the continuously changing cutter feed direction), only the cutter surface normal direction has been applied to the determination of the undeformed chip thickness [33,34].…”

Section: Undeformed Chip Thickness Determination Directionmentioning

confidence: 99%

Cutting force prediction for ball-end mills with non-horizontal and rotational cutting motions

Azeem

Feng

2012

Int J Adv Manuf Technol

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Accurate cutting force prediction is essential to precision machining operations as cutting force is a process variable that directly relates to machining quality and efficiency. This paper presents an improved mechanistic cutting force model for multi-axis ball-end milling. Multi-axis ballend milling is mainly used for sculptured surface machining where non-horizontal (upward and downward) and rotational cutting tool motions are common. Unlike the existing research studies, the present work attempts to explicitly consider the effect of the 3D cutting motions of the ballend mill on the cutting forces. The main feature of the present work is thus the proposed generalized concept of characterizing the undeformed chip thickness for 3D cutter movements. The proposed concept evaluates the undeformed chip thickness of an engaged cutting element in the principal normal direction of its 3D trochoidal trajectory. This concept is unique and it leads to the first cutting force model that specifically applies to non-horizontal and rotational cutting tool motions. The resulting cutting force model has been validated experimentally with extensive verification test cuts consisting of horizontal, non-horizontal, and rotational cutting motions of a ball-end mill.

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Cutting force prediction of sculptured surface ball-end milling using Z-map

Cited by 154 publications

References 10 publications

The influence of cutting force on surface machining quality

The influence of cutting force on surface machining quality

Prediction and Experimental Validation of Cutting Force for Bull-Nose End Mills with Lead Angle

Cutting force prediction for ball-end mills with non-horizontal and rotational cutting motions

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