Estimation of cutter deflection and form error in ball-end milling processes

Kim, G.M.; Kim, B.H.; Chu, Chong Nam

doi:10.1016/s0890-6955(03)00056-7

Cited by 132 publications

(80 citation statements)

References 11 publications

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“…On the other hand, in the contouring tool-path styles, the cutter scans an inclined surface following the lines perpendicular to the surface radius. [15][16][17] In this study, the step-over values are kept constant in both tool-path styles. After each step of the machining, the cutter moves one step sideways to the position, in which it returns back to the staring level of that step and then makes the next step.…”

Section: Tool-path Strategies and Cutting Parametersmentioning

confidence: 99%

Effects of cutting parameters and tool-path strategies on tool acceleration in ball-end milling

Gök¹,

Gök²,

Bilgin³

et al. 2017

Mater. Tehnol.

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The determination of the cutting-parameter values that cause increases in vibration values is important to minimize the errors that can occur. Thus, the first aim of this study was to investigate the optimum cutting-parameter values and tool-path strategies in ball-end milling of the EN X40CrMoV5-1 tool steel with three coated cutters using the Taguchi method. The parameters taken into consideration are the cutting speed, feed rate, step over and tool-path strategies. The second aim of the study, a model for the tool acceleration as a function of the cutting parameters, was obtained using the response-surface methodology (RSM). As a result, the most effective parameter within the selected cutting parameters and cutting strategies for both inclined surfaces and different coatings was the step over. In terms of tool coatings, the most deteriorating coating for the tool acceleration on both inclined surfaces was the TiC coating. In addition, the response-surface methodology is employed to predict the tool-vibration values depending on the cutting parameters and tool-path strategy. The model generated gives highly accurate results. Keywords: inclined surfaces, ball-end milling, tool acceleration, Taguchi method, response-surface methodology, response optimization Neoptimalni rezalni parametri med mehansko obdelavo lahko povzro~ijo ne`elene vibracije in posledi~no napake. Prvi cilj avtorjev te {tudije je bil dolo~iti optimalne vrednosti rezalnih parametrov in strategije potovanja orodja med mehansko obdelavo orodnega jekla EN X40CrMoV5-1 s krogli~nim frezalom s tremi rezili z razli~no prevleko (TiC, TiN in TiAlN). Za to so uporabili Taguchi-jevo metodo. Parametri, ki so jih avtorji zajeli v {tudiji so bili: hitrost rezanja, velikost odvzema, korak odvzema (preskok) in strategija poti orodja. Drugi cilj avtorjev te {tudije je bil izdelati model pospe{evanja orodja v odvisnosti od rezalnih parametrov, z uporabo metodologije odziva povr{ine (angl. RSM). Ugotovili so, da je korak odvzema (angl.: step over) naju~inkovitej{i parameter med izbranimi rezalnimi parametri in rezalnimi strategijami, tako za oba izbrana nagiba (ukrivljenosti) povr{ine, kot tudi izbrane trde prevleke. Med izbranimi trdimi prevlekami se je v vseh pogojih frezanja kot najslab{a izkazala TiC prevleka. RSM metodologija dodatno omogo~a napoved vibracij orodja v odvisnosti od rezalnih parametrov in izbrane strategije poti orodja. Izdelani model daje zelo to~ne rezultate. Klju~ne besede: nagib (ukrivljenost) povr{ine, mehanska obdelava s krogli~nim frezalom, pospe{ek orodja, Taguchi metoda, metodologija odgovora povr{ine, optimizacija odgovora

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Section: Tool-path Strategies and Cutting Parametersmentioning

confidence: 99%

Effects of cutting parameters and tool-path strategies on tool acceleration in ball-end milling

Gök¹,

Gök²,

Bilgin³

et al. 2017

Mater. Tehnol.

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show abstract

“…The cutting forces are influenced by several factors, such as tool geometry, properties of the workpiece material, cutting conditions, etc. [7], cause deflections in the cutting system by tool-workpiece-machine [8], which cause significant geometrical errors in the machined workpiece [9]. These errors are particularly important when a high tool length/diameter ratio is used, when the inclination of the machined surface is high and when tool wear is significant [10].…”

Section: Introductionmentioning

confidence: 99%

Cutting force analysis in machining of titanium alloy with solid carbide cutters of different geometriy

2018

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Abstract. In order to study the cutting force in machining of titanium alloy with solid carbide cutters of different geometriy, variable helix (VH), variable pitch (VP) and standard (SD) milling cutter were used to machine titanium alloy TB6 via dry milling. The influence of cutting parameters and geometric structure parameters of milling cutters on the cutting force was investigated by the analysis of radial and tangential forces in the cutting process with three kinds of milling cutters. The experiment results showed that cutting parameters had the same influence on the radial force and tangential force of the three milling cutters, and the influence of geometric structure parameters on radial force and tangential force was different. Compared with the SD milling cutter, the change of pitch and helix resulted in the increase of radial and tangential forces, the pitch change led to the radial force being larger than the tangential force, and the helix change led to the radial force being smaller than the tangential force.

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“…These processes are very often carried out in finish conditions, thus the high quality of the machined surface is required. Nevertheless, many researches [1][2][3] show that fundamental problems occurring during ball end milling in finish conditions are the excessive surface roughness and surface location errors, as well as the intense tool wear [22]. The deterioration of surface quality during machining can be attributed to machine tool-cutting process interactions, as: milling kinematics [4,5], the loss of process stability [6,23], elastic-plastic deformations of workpiece [7,8], as well as the tool's working part displacements (vibrations) [9,10].…”

Section: Introductionmentioning

confidence: 99%

The study on dynamic properties of monolithic ball end mills with various slenderness

et al. 2017

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Abstract. The reliable determination of modal mass, damping and stiffness coefficient (modal parameters) for the particular machine-toolholder-tool system is essential for the accurate estimation of vibrations, stability and thus the machined surface finish formed during the milling process. Therefore, this paper focuses on the analysis of ball end mill's dynamical properties. The tools investigated during this study are monolithic ball end mills with different slenderness values, made of coated cemented carbide. These kinds of tools are very often applied during the precise milling of curvilinear surfaces. The research program included the impulse test carried out for the investigated tools clamped in the hydraulic toolholder. The obtained modal parameters were further applied in the developed tool's instantaneous deflection model, in order to estimate the tool's working part vibrations during precise milling. The application of the proposed dynamics model involved also the determination of instantaneous cutting forces on the basis of the mechanistic approach. The research revealed that ball end mill's slenderness can be considered as an important milling dynamics and machined surface quality indicator.

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Estimation of cutter deflection and form error in ball-end milling processes

Cited by 132 publications

References 11 publications

Effects of cutting parameters and tool-path strategies on tool acceleration in ball-end milling

Effects of cutting parameters and tool-path strategies on tool acceleration in ball-end milling

Cutting force analysis in machining of titanium alloy with solid carbide cutters of different geometriy

The study on dynamic properties of monolithic ball end mills with various slenderness

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