Modelling of cutting forces in ball-end milling with tool–surface inclination

Fontaine, Michaël; Moufki, Abdelhadi; Devillez, Arnaud; Dudzinski, D.

doi:10.1016/j.jmatprotec.2007.01.006

Cited by 102 publications

(38 citation statements)

References 29 publications

(46 reference statements)

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“…While Ozturk and Tunc presented the detailed analysis of lead and tilt angle's effects on cutting forces, torque, form errors and stability [16]. Also researches that dealt with the effects of tool-surface inclination on ball end mill cutting forces were conducted by using thermomechanical modeling of oblique cutting [17,18]. Based on this model, Fontaine et al launched several experiments with straight tool paths and various tool-surface inclinations on a 3-axis machine.…”

Section: Advances In Mechanical Engineeringmentioning

confidence: 99%

“…Based on this model, Fontaine et al launched several experiments with straight tool paths and various tool-surface inclinations on a 3-axis machine. By doing this, it identified the optimized inclination angle as well as the influences of cutting condition, radial runout, ploughing, and cutting stability on ball-end mill [18]. 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].…”

Section: Advances In Mechanical Engineeringmentioning

confidence: 99%

“…A case in point is that the measured cutting force cannot be used directly, whereas they should be recalculated by the current layer and its previous adjacent one. For instance, the functional value adopted by the above model has the expressions in (18). However, in the formulations, { 1 , 2 ⋅ ⋅ ⋅ } represents the cutting force corresponding to the {1, 2 ⋅ ⋅ ⋅ }th element along cutter edge…”

Section: Identification Of Specific Force Coefficientsmentioning

confidence: 99%

See 2 more Smart Citations

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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Section: Advances In Mechanical Engineeringmentioning

confidence: 99%

Section: Advances In Mechanical Engineeringmentioning

confidence: 99%

Section: Identification Of Specific Force Coefficientsmentioning

confidence: 99%

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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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“…Horizontal ball-end milling only has very limited applications as ball-end mills are often used in three-or multi-axis sculptured surface machining, where non-horizontal and/or rotational cutting motions are common. For non-horizontal ball-end milling cuts, researchers have consistently applied one of the two existing directions: cutter surface normal direction [25][26][27][28] and horizontal direction [29][30][31]. Nonetheless, these two directions, as originally proposed for horizontal cuts, may not characterize non-horizontal and rotational cuts correctly.…”

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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“…Lee and Altintas [17] put forward the identification method for the coefficients of cutting force from the orthogonal cutting data. Fontaine et al [18] studied the effect of tool-surface inclination for the cutting force in ballend milling. However, the above researches mainly aim to the plane face machining with constant cutting condition.…”

Section: Introductionmentioning

confidence: 99%

A new cutting force modeling method in high-speed milling of curved surface with difficult-to-machine material

Zhang

Wang

et al. 2015

Int J Adv Manuf Technol

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The high-speed milling technology for difficultto-machine material has come to be a hotspot in the industry field. Regarding the high-speed milling of Inconel 718 parts with curved surface, the variation of the geometric features of the curved surface will lead to the sharp fluctuation of the cutting force as well as the vibration of machine tool. In this way, it not only makes a severe impact on the surface machining quality and the tool life but also greatly affects the efficiency of the high-speed milling. For the milling force is an important physical concept to comprehensively reflect the milling process and the cutting speed is one of the main factors that affect the cutting force when the cutting volume is small in the high-speed milling of Inconel 718 parts with curved surface, a new cutting force modeling method is proposed based on the geometric characteristics of the curved surface and the spindle speed, which can be used to predict the cutting force fluctuation under different cutting speed. The experimental results show that the proposed cutting force model can effectively forecast the amplitude and the change trend of the cutting force. The achievements of this study will provide the theoretical basis for the optimization of machining parameters in high-speed milling of curved surface with difficult-to-machine material and enrich the processing and manufacturing theory for parts with curved surface.

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Modelling of cutting forces in ball-end milling with tool–surface inclination

Cited by 102 publications

References 29 publications

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

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

A new cutting force modeling method in high-speed milling of curved surface with difficult-to-machine material

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