Simulation of cutting forces in ball-end milling

Milfelner, M.; Čuš, F.

doi:10.1016/s0736-5845(02)00066-2

Cited by 30 publications

(31 citation statements)

References 5 publications

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“…Figure 1 shows the schematic diagram of a cutter of a ball-end milling and its configuration parameters. The following is the main idea how to calculate it [31,32]. The lag between the tip of the flute at 0 z  and at axial location z is [30] 0 0…”

Section: Flexible Force Model For Thin-wall Workpiecementioning

confidence: 99%

Finite Element Analysis of Machining Thin-Wall Parts: Error Prediction and Stability Analysis

Huang¹,

Zhang²,

Xiong³

2012

Finite Element Analysis - Applications in Mechanical Engineering

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Section: Flexible Force Model For Thin-wall Workpiecementioning

confidence: 99%

Finite Element Analysis of Machining Thin-Wall Parts: Error Prediction and Stability Analysis

Huang¹,

Zhang²,

Xiong³

2012

Finite Element Analysis - Applications in Mechanical Engineering

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“…These parameters are bound by a model of cutting forces (Milfelner and Cus, 2003). These coefficients necessarily vary according to the slope of the trajectory to be machined, and also according to the cutting conditions such as: feed per tooth f zb , the cutting speed V c and the depth of cut: axial A d and radial A r .…”

Section: Determination Of the Specific Coefficientsmentioning

confidence: 99%

“…The specific coefficients K T , K R and K A are determined from the following equation (Milfelner and Cus, 2003):…”

Section: Determination Of the Specific Coefficientsmentioning

confidence: 99%

Compensation of a ball end tool trajectory in complex surface milling

Smaoui¹,

Bouaziz²,

Zghal³

et al. 2012

IJMMM

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OATAO is an open access repository that collects the work of Toulouse researchers and makes it freely available over the web where possible. Abstract: This work is consecrated to the minimising of machining errors based on a method for the compensation of the trajectory to be machined in hemispherical milling. This compensation is found to be necessary because of the tool deflection due to the cutting forces. In order to remedy to the machining errors, caused by this deflection, a compensation method has been proposed. The latter is inspired from the mirror method, since the compensated position is going to be determined as being the trajectory reflection, deviated onto the mirror. The advantage of this proposed method is that it takes into account the three deflections d x , d y and d z , respectively to the directions X, Y and Z. After that, two-parallel machinings, separated by a groove and achieved absolutely in the same conditions and with the same tool, are carried out, on the same complex part. The first machining is with compensation, but the second is without compensation. Compensation of a ball end tool trajectory inThe coordinates of the two obtained surfaces are recorded by a 3D measuring machine. The comparison of the two-surfaces shows the presence of an important correction of the tool trajectory, and reveals a similarity between the part obtained by simulation and the one conceived in CAM.

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“…The undeformed chip thickness was determined in the cutter surface normal direction. This direction was later adopted by several other researchers [11][12][13][14][15]. In contrast, Feng and Menq [16] formulated their mechanistic cutting force model for ball-end milling by defining the undeformed chip thickness as the radial distance between two consecutive cutting edge trajectories in the horizontal direction.…”

Section: Introductionmentioning

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.

show abstract

Simulation of cutting forces in ball-end milling

Cited by 30 publications

References 5 publications

Finite Element Analysis of Machining Thin-Wall Parts: Error Prediction and Stability Analysis

Finite Element Analysis of Machining Thin-Wall Parts: Error Prediction and Stability Analysis

Compensation of a ball end tool trajectory in complex surface milling

Cutting force prediction for ball-end mills with non-horizontal and rotational cutting motions

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