Modeling on the Milling Force of Ball-end Milling Cutter Based on Z-MAP Method

Dong, Yongheng; Li, Shujuan; Xiantao, Hong; Li, Pengyang; Li, Yan; Li, Qi

doi:10.3901/jme.2019.19.201

Cited by 6 publications

(2 citation statements)

References 0 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Where OX j Y j Z j is the cutter tooth coordinate system, which rotates with the cutting edge at an angular velocity ω . The coordinates of any point P j on the helix cutting edge under OX j Y j Z j are expressed as Equation (1) [ 36 , 37 ].…”

Section: Methodsmentioning

confidence: 99%

Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4V

et al. 2021

View full text Add to dashboard Cite

Ball-end cutters are widely used for machining the parts of Ti-6Al-4V, which have the problem of poor machined surface quality due to the low cutting speed near the tool tip. In this paper, through the experiments of inclined surface machining in different feed directions, it is found that the surface adhered damages will form on the machined surface under certain tool postures. It is determined that the formation of surface adhered damage is related to the material adhesion near the cutting edge and the cutting-into/out position within the tool per-rotation cycle. In order to analyze the cutting-into/out process more clearly under different tool postures, the projection models of the cutting edge and the cutter workpiece engagement on the contact plane are established; thus, the complex geometry problem of space is transformed into that of plane. Combined with the case of cutting-into/out, chip morphology, and surface morphology, the formation mechanism of surface adhered damage is analyzed. The analysis results show that the adhered damage can increase the height parameters Sku, Sz, Sp, and Sv of surface topographies. Sz, Sp, and Sv of the normal machined surface without damage (Sku ≈ 3) are about 4–6, 2–3, and 2–3 μm, while Sz, Sp, and Sv with adhered damage (Sku > 3) can reach about 8–20, 4–14, and 3–6 μm in down-milling and 10–25, 7–18, and 3–7 μm in up-milling. The feed direction should be selected along the upper left (Q2: β∈[0°, 90°]) or lower left (Q3: β∈[90°, 180°]) to avoid surface adhered damage in the down-milling process. For up-milling, the feed direction should be selected along the upper right (Q1: β∈(−90°, 0°]) or upper left (Q2: β∈[0°, 90°)).

show abstract

Section: Methodsmentioning

confidence: 99%

Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4V

et al. 2021

View full text Add to dashboard Cite

show abstract

“…Kazuki [25] and Li [26] modeled the milling force of a ball-end milling cutter considering changes in the microelement friction angle, shear angle, and shear stress constraints using microelement diagonal shear theory. Falta [27] and Dong [28] used an analytical modeling method for predicting the static milling force of a ball-end milling cutter by establishing a tool-workpiece engagement region. The removal mechanism of materials can be deeply analyzed through the physical analytical model; however, the physical analytical model is closely related to material constitutive parameters, which are difficult to obtain.…”

Section: Introductionmentioning

confidence: 99%

Milling Mechanism and Chattering Stability of Nickel-Based Superalloy Inconel 718

Zheng,

Zhang,

Qiao

2023

Materials

View full text Add to dashboard Cite

Nickel-based superalloy Inconel 718 is widely used in the aerospace industry for its excellent high-temperature strength and thermal stability. However, milling Inconel 718 presents challenges because of the significantly increased cutting force and vibration, since Inconel 718 is a typical difficult-to-machine material. This paper takes the milling process of Inconel 718 as the research object, initially, and a milling force model of Inconel 718 is established. Subsequently, the finite element analysis method is used to analyze the stress field, temperature field, and milling force in the milling process of Inconel 718. Building upon this, a dynamic equation of the milling of Inconel 718 is established, and based on the modal experiment, stability lobe diagrams are drawn. Furthermore, milling experiments on Inconel 718 are designed, and the results calculated using the milling force model and finite element analysis are verified through comparison to the experimental results; then, the fmincon optimization algorithm is used to optimize the processing parameters of Inconel 718. Eventually, the results of the multi-objective optimization illustrate that the best processing parameters are a spindle speed of 3199.2 rpm and a feed speed of 80 mm/min with an axial depth of cut of 0.25 mm. Based on this, the best machining parameters are determined, which point towards an improvement of the machining efficiency and quality of Inconel 718.

show abstract

Modified cutting force prediction model considering the true trajectory of cutting edge and in-process workpiece geometry in ball-end milling operation

Wang

Zhang

et al. 2021

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Modeling on the Milling Force of Ball-end Milling Cutter Based on Z-MAP Method

Cited by 6 publications

References 0 publications

Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4V

Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4V

Milling Mechanism and Chattering Stability of Nickel-Based Superalloy Inconel 718

Modified cutting force prediction model considering the true trajectory of cutting edge and in-process workpiece geometry in ball-end milling operation

Contact Info

Product

Resources

About