Model development for the prediction of surface topography generated by ball-end mills taking into account the tool parallel axis offset. Experimental validation

Arizmendi, M.; Fernández, J.; Lacalle, Luís Norberto López de; Lamíkiz, Aitzol; Gil, Alain Manuel Chaple; Sánchez, J.A.; Campa, Francisco J.; Veiga, Fernando

doi:10.1016/j.cirp.2008.03.045

Cited by 85 publications

(34 citation statements)

References 5 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…In order to investigate the thermal effect, theoretical modeling, predicting, and optimization analysis based on numerical simulation are frequently performed [5][6][7]. Kim et al estimated the two-dimensional temperature distributions of a ball screw system at various moving speeds by finite element method [8].…”

Section: Introductionmentioning

confidence: 99%

Experiment-based thermal error modeling method for dual ball screw feed system of precision machine tool

Shi

Zhang

Yang

et al. 2015

Int J Adv Manuf Technol

View full text Add to dashboard Cite

In order to investigate the thermal behavior of a dual ball screw feed drive system of a precision boring machine tool, experimental study on and theoretical modeling of thermally induced error along with heat generation characteristics are conducted in this paper. Experiments are carried out on the machine tool to measure and collect the thermodynamic information with its feed drive system operating under different working conditions. Based on the real-time data of the thermal expansion of ball screw in the axial direction, relationships between the thermal error and axial elongation are established to predict the thermal error distribution. The results show that the thermal error varies with different working position through the ball screw length linearly and with working time nonlinearly. In addition, another simplified way to model thermal error is presented to overcome the difficulties existing in the ball screw feed drive system of which the axial elongation is hard to collect. Fuzzy clustering and linear regression methods are employed to carry out the theoretical modeling of thermal error and optimization to sift out the critical heat sources. With the temperature data of these critical heat generation points, the thermally induced error of the ball screw feed drive system can be predicted easily alternatively. Experiments under a different condition are preformed to verify both prediction and modeling methods. It turns out that the proposed prediction methods are effective and practical to be used in the machining process as well.

show abstract

Section: Introductionmentioning

confidence: 99%

Experiment-based thermal error modeling method for dual ball screw feed system of precision machine tool

Shi

Zhang

Yang

et al. 2015

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…Sylvain et al [2] developed a simulation model for the prediction of machined surface patterns based on the well-known N-buffer method, and the proposed model can be coupled to a feed-rate prediction model in sculptured surface machining. Arizmend et al established a model for the topography prediction of ballend milled surfaces, considering the tool parallel axis offset, which is solved by transforming them to polynomial equations through Chebyshev expansions [3] and then present a model for the prediction of surface topography in peripheral milling operations taking into account the tool vibrates during the cutting process, which are transformed into equivalent polynomial equations and solved for discrete positions along the feed direction by applying a standard root finder [4]. Quinsat et al [5,6] studied the influence of 3D surface roughness parameter on 3D surface topography, and an analysis of the patterns obtained for various sets of machining parameters serves to highlight those that influence 3D surface topography and proposed a simulation model of material removal in five axes based on the N-buffer method and integrating the inverse kinematics transformation.…”

Section: Introductionmentioning

confidence: 99%

“…The on-line simulation method and software realization of simulation algorithm are given in Sect. 3. Section 4 provides an example of surface topography simulation and experiments.…”

Section: Introductionmentioning

confidence: 99%

Modeling and on-line simulation of surface topography considering tool wear in multi-axis milling process

Zhang

et al. 2014

Int J Adv Manuf Technol

View full text Add to dashboard Cite

The understanding and prediction of the generated surface topography are very important in milling process. This paper presents a surface topography model and an on-line simulation method of surface topography considering tool wear in a multi-axis milling process. First, the cutting edge equation is established by dividing the cutting edge into a series of cutting edge elements considering tool wear influence and tilt angle of tool axis on each discrete cutting edge element, and an algorithm is proposed to determine the range of divided position angle. Then, the sculptured surface workpiece is divided into a series of elements along the feed direction with the same or less than discrete precision of cutting edge. The intersection points between the discrete cutting edge elements and the planes of both sides of each divided element on workpiece can be obtained based on the established cutting edge equation in the cutting process. The left cutting trajectory points on workpiece are got by reserving the points with the minimum coordinate value in the Z-axis direction under the same coordinate value in the X-axis and Yaxis direction among the intersection points and points on workpiece. Thus, surface topography model can be constructed based on the established cutting edge equation, the determined range of position angle, discrete cutting edge elements, and divided element on workpiece surface. Finally, an on-line simulation algorithm is proposed to simulate the generation process of surface topography in multi-axis milling operation. Experimental work and validation of the established model are performed on a five-axis milling center by using stainless steel 0Cr17Ni12Mo2 and cemented carbides milling cutter. The results about the topography generation of the constructed B-spline surface show that the predictions of the established surface topography model correlate well with the experimental results.

show abstract

“…Several works had been carried out to investigate the stiffness and defection of the cutting tool system which will affect the machining precision and surface quality (Salgado et al 2005). Some scholars focus on the estimation of the geometrical accuracy in multi-axis milling process (Lamikiz et al 2008) and the topography prediction of ball-end milled surfaces, considering the tool parallel axis offset (Arizmendi et al 2008). However, the deformation of the matching of LSFH and cutting tool is particularly prominent during the machining process due to the special lengthening structure of LSHF.…”

Section: Introductionmentioning

confidence: 99%

Error compensation in high-speed milling of deep cavity dies and molds based on the lengthened shrink-fit holder

Zhou

Liu

Zhou

et al. 2015

Int J Mech Mater Eng

View full text Add to dashboard Cite

Background: In high speed milling of the dies and molds characterized by large-scale and deep cavities with the lengthened shrink-fit holder (LSFH), the machining error caused by the tool deflection is not allowed to be ignored. Methods: The deformation of the LSFH and cutting tool are predicted, and at the same time the machining error caused by this deformation are predicted too based on the milling force prediction model and the finite element model. Taking into account the complex mutual coupling between milling force and the deformation, an error compensation method is proposed based on a balancing iterative algorithm. Results: The compensation tool path is obtained and the off-line machining error compensation is achieved. Milling example shows that the machining error after compensation less 77.4 % than that of no compensation.Conclusions: The results demonstrate that the proposed error compensation method is reasonable and can greatly reduce the machining error.

show abstract

Model development for the prediction of surface topography generated by ball-end mills taking into account the tool parallel axis offset. Experimental validation

Cited by 85 publications

References 5 publications

Experiment-based thermal error modeling method for dual ball screw feed system of precision machine tool

Experiment-based thermal error modeling method for dual ball screw feed system of precision machine tool

Modeling and on-line simulation of surface topography considering tool wear in multi-axis milling process

Error compensation in high-speed milling of deep cavity dies and molds based on the lengthened shrink-fit holder

Contact Info

Product

Resources

About