Prediction of cutting forces in ball-end milling by means of geometric analysis

Tsai, Chung-Liang; Liao, Yunn‐Shiuan

doi:10.1016/j.jmatprotec.2007.11.083

Cited by 39 publications

(16 citation statements)

References 8 publications

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“…Generally speaking, researchers in the past consider that the force-based model gives more precise prediction comparing to the volumetric model. However, force model is not general as various milling forces can be produced under different cutting conditions even with the same MRR (e.g., [6]- [9]). They are mainly developed for the purpose of surface finishing.…”

Section: B Related Workmentioning

confidence: 99%

Progressive segmentation for MRR-based feed-rate optimization in CNC machining

Chan

Wang

2015

2015 IEEE International Conference on Automation Science and Engineering (CASE)

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Keeping a constant cutting force in CNC machining is very important for obtaining better stability of cutting operation and improving topography, texture and geometry of the machined surface. This paper presents a feed-rate optimization approach based on Material Removal Rate (MRR). Given a tool-path with predefined feed-rates, the geometry of raw material, and the shape of cutter, the histogram of MRR in very fine resolution can be efficiently computed by using a GPU-based geometric modeling kernel. Starting from the evaluation given on the finest histogram of MRR, errorcontrolled subdivision algorithms are developed to progressively segment the tool-path into user-specified number of sub-regions. Different feed-rates are assigned to different sub-regions so that nearly constant MRR can be achieved while keeping the shape of the given tool-path unchanged. Experimental tests taken on real examples verify the effectiveness of this method.

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Section: B Related Workmentioning

confidence: 99%

Progressive segmentation for MRR-based feed-rate optimization in CNC machining

Chan

Wang

2015

2015 IEEE International Conference on Automation Science and Engineering (CASE)

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“…19,20,24,26 With regard to the oblique cutting process, the extrusion effects between the tool rake face and the back surface of the in-process chip are produced during the chip formation process, and meanwhile, the extrusion effects between the tool flank face and the free surface of the uncut chip in the following machining operation are also generated.…”

Section: Analysis Of Chip Under Rough Milling Conditionmentioning

confidence: 99%

Investigation on the chip formation concerning tool inclination angles in ball end milling of H13 die steel

Chen

Zhao

Liu

et al. 2013

Proceedings of the Institution of Mechanical Engineers, Part B:

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Widespread application of ball end milling operation is an outstanding characteristic in the field of manufacturing of die and molds. Tool inclination angles, which could improve the cutting performance of ball end mill, are critical factor in the ball end milling process, and also chip formation is one of the most important phenomena in the machining process. Numerical simulation, geometric analysis, observation by optical microscope and scanning electron microscope, and energy-dispersive spectroscopy analysis were adopted to study the chip formation during ball end milling of H13 die steels involving tool inclination angles in this work. The theoretical uncut chip geometry and tool-work contact zone were analyzed by computer-aided modeling technology. Finite element modeling of chip formation process involving tool inclination angles was performed, and variations of the maximum chip temperature which could provide assistant understanding of practical chip formation were analyzed. This article also investigated the practical chip morphologies, chip color, and the cutting characteristics under different process conditions and tool inclination angles. The optical microscope and scanning electronic microscope were used to capture the micro-photos of the chips under different process parameters, and the chip color and chip morphologies were discussed together with the cutting characteristics with regard to various process parameters. Energy-dispersive spectroscopy analysis of the chip free surface and back surface was also carried out for some special tool inclination angles. Deep understanding of the chip formation in multi-axis milling process was enhanced, and the research work could provide support for the selection of process parameters to some extent.

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“…CHING-CHIH Tai et al [9] proposed a cutting force model which predicts the force system in ball-end milling over a wider range of cutting conditions, cutter geometries, workpiece, and process geometries including the eccentricity inevitably found in practice. Chung-Liang Tsai et al [10] developed a new three-dimensional cutting model in ball-end milling process, in which the flute was divided into small cutting edges. In the model, there is an assumption that an average cutting velocity is the cutting velocity.…”

Section: The Nechanical Model Of Ball-endmentioning

confidence: 99%

The simulation of cutting force of free-form surface machining with ball-end milling cutter

Shi

Liu

Zhang

et al. 2009

2009 IEEE International Conference on Industrial Engineering and Engineering Management

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Based on the previous researches and according to the milling characteristics of ball-end milling cutter, the cutting force model is established. Using empirical formula, the feed rate of NC codes of machining free-form surface is optimized under constraint of nearly constant cutting force, and so as to decrease the fluctuation of cutting force. Thus, the machining quality and efficiency of part are improved and the service life of cutting tool is prolonged. This paper develops a prototype system under constraint of nearly constant cutting force. And an example is given to verify the effectiveness of the method. This paper lays a good foundation for the development of software module of cutting parameter optimization related to freeform surface machining. Keywordsconstraint under nearly constant cutting force, cutting force model, free-form surface, feed rate optimization, simulation of cutting force 978-1-4244-4870-8/09/$26.00 ©2009 IEEE Proceedings of the 2009 IEEE IEEM

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Prediction of cutting forces in ball-end milling by means of geometric analysis

Cited by 39 publications

References 8 publications

Progressive segmentation for MRR-based feed-rate optimization in CNC machining

Progressive segmentation for MRR-based feed-rate optimization in CNC machining

Investigation on the chip formation concerning tool inclination angles in ball end milling of H13 die steel

The simulation of cutting force of free-form surface machining with ball-end milling cutter

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