Study on surface defects in five-axis ball-end milling of tool steel

Wang, P.; Zhang, S.; Yan, Zhenguo

doi:10.1007/s00170-016-9113-3

Cited by 6 publications

(4 citation statements)

References 21 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…According to the engineering and cutting parameters manual, the value range of feed per tooth is 0~1 mm, the value range of the radial depth of cut is 0~1 mm, the value range of the axial depth of cut is 0~1 mm, the value of the spindle speed is 3000~10,000 r/min, and the lead and tilt angles are 0~45 • . In order to deeply understand the influences of changes in cutting parameters on the five-axis ball-end milling process, five values of each factor have been selected according to the actual engineering and cutting parameters manual, as shown in [31]. Three arbitrary experiments under different cutting parameters (see Table 3) were selected to validate the developed surface topography model.…”

Section: Experimental Verificationmentioning

confidence: 99%

Modelling and Optimization of Machined Surface Topography in Ball-End Milling Process

Wang,

Zhao,

Tan

et al. 2024

Materials

View full text Add to dashboard Cite

In order to optimize machined surface topography, this paper presents a novel algorithm for simulating the surface topography and predicting the surface roughness of a ball-end milling process. First, a discrete workpiece model was developed using the Z-map method, and the swept surface of a cutter edge was represented using triangular approximation. The workpiece surface was updated (i.e., material removal process) using the intersection between the vertical reference line and the triangular facet under a cutting judgement. Second, the proposed algorithm was verified by comparing the simulated 3D surface topography as well as 2D surface profile and average roughness (Sa) with experimental measurements. Then, numerical simulation examples planed by the Box–Behnken design methods were carried out to investigate the Sa in the ball-end milling operation. The correlations of Sa and cutting parameters were represented by a response surface reduced quadratic model based on the ANOVA results. Finally, the feed per tooth, radial depth of cut, and tilt and lead angles were optimized for improving the machining efficiency under the Sa constraints. This study presents an effective method for simulating surface topography and predicting the Sa to optimize the cutting parameters during ball-end milling process.

show abstract

Section: Experimental Verificationmentioning

confidence: 99%

Modelling and Optimization of Machined Surface Topography in Ball-End Milling Process

Wang,

Zhao,

Tan

et al. 2024

Materials

View full text Add to dashboard Cite

show abstract

“…According to similar studies such as [28][29][30][31], this difference is provoked mainly by the physical imperfections of the machining system. Factors such as cutting tool vibration, defects in the homogeneity of the work piece material, undeformed chip thickness variation, built-up edge and tearing of the work piece material play roles at different levels in altering the generated profile and hence the global surface roughness.…”

Section: Modelling Of the Surface States Obtained Via End Milling Pro...mentioning

confidence: 99%

Effect of end milling, grinding and tartaric-sulfuric anodizing on the fatigue behavior of AA7050 alloy

Abroug

Pessard

Germain

et al. 2022

Int J Adv Manuf Technol

View full text Add to dashboard Cite

The present study investigates the effect of the high-speed milling (HSM), grinding and anodizing processes on the high cycle fatigue strength of the AA7050 aluminum alloy. These processes are systematically applied to certain aircraft components as specified by aeronautical standards, to attain a good surface finish. In order to understand the effect of each process on the fatigue strength, a vast experimental campaign consisting of fully reversed plane bending fatigue tests has been conducted on specimens with different surface states. A polished batch, three milled batches with different surface roughness, a grinded batch and two milled then anodized batches with different surface roughness have been tested. The results show that the roughness must be highly degraded (Sa > 3 m ) in order to impact the fatigue strength. It is also shown that anodizing has slight beneficial effect on the fatigue strength in the high cycle fatigue domain studied. The experimental results show a dependence of the fatigue strength on the surface roughness via the parameter √ Sa , previously proposed by the authors.

show abstract

“…Many analytical studies [14][15][16][17][18][19][20][21][22] addressed the issue on toroidal cutter in five-axis milling by simply approximating an inclined cutter geometry by two common primitive geometries, either circle or ellipse. Senatore et al [16] represent the tool swept envelope by calculating the effective radius of toroidal cutter due to the inclination angle.…”

Section: Introductionmentioning

confidence: 99%

“…Then, the scallop height with respect to radius of part surface is calculated and finally the optimal step-over can be determined. Others studies [17][18][19][20][21][22] defined the inclined flat and ball end mills as an ellipse. Mathematically, the shape of swept curves of inclined flat and ball end mill, which are projected into 2D, can be precisely determined by parametric equation of ellipse curve.…”

Section: Introductionmentioning

confidence: 99%

A hybrid analytical and discrete based methodology to calculate path scallop of helical toroidal cutter in five-axis milling

Hendriko¹

2018

FME Transactions

View full text Add to dashboard Cite

This paper presents a new method to calculate path scallop height of toroidal cutter during free-form surface machining in five-axis milling. The scallop height was defined as the distance between the tool intersection point and the normal point on the part surface. The tool intersection point was determined analytically by implementing the grazing method to define the swept curve of toroidal cutter. Meanwhile the normal surface on the part surface was determined using a hybrid analytical and discrete based methodology. The part surface was discretized by a number of normal vectors, then, they were used for defining the part surface mathematically. In this study,the effect of helical angle of cutting edge was taken into consideration in the model development. The proposed model was successfully used to generate the path scallop data for two model parts with free-form surface profiles. The effect of helical angle to the scallop height was also tested and the results showed that the helical angle tends to decrease the scallop height. The verification test to check the accuracy of the proposed method was performed and the results proved that the method was accurate.

show abstract

Study on surface defects in five-axis ball-end milling of tool steel

Cited by 6 publications

References 21 publications

Modelling and Optimization of Machined Surface Topography in Ball-End Milling Process

Modelling and Optimization of Machined Surface Topography in Ball-End Milling Process

Effect of end milling, grinding and tartaric-sulfuric anodizing on the fatigue behavior of AA7050 alloy

A hybrid analytical and discrete based methodology to calculate path scallop of helical toroidal cutter in five-axis milling

Contact Info

Product

Resources

About