Surface finish visualisation in high speed, ball nose milling applications

Liu, Ning; Loftus, Martin; Whitten, Andrew E.

doi:10.1016/j.ijmachtools.2004.12.007

Cited by 38 publications

(21 citation statements)

References 8 publications

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“…Moreover an optimisation of the feed rate is proposed according to the tool inclination. Liu et al detail a method based on the solid modelling of each cutter flute [20]. The workpiece surface is discretized in the (XY) plane by parallel lines (called spikes) to the Z axis (tool axis).…”

Section: Introductionmentioning

confidence: 99%

Model for the prediction of 3D surface topography in 5-axis milling

Lavernhe

Quinsat

Lartigue

2010

Int J Adv Manuf Technol

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Abstract:The paper deals with the prediction of the 3D surface topography obtained in 5-axis milling in function of the machining conditions. For this purpose, a simulation model for the prediction of machined surface patterns is developed based on the well-known N-buffer method. As in sculptured surface machining the feed rates locally vary, the proposed model can be coupled to a feed rate prediction model. Thanks to the simulation model of 3D surface topography, the influence of the machining strategy on resulting 3D surface patterns is analyzed through an experimental design. Results enhance the major influence of the tool inclination on 3D topography. Surface parameters used in the study are strongly affected by the variation of the yaw angle. The effect of the feed rate is also significant on amplitude parameters. Finally, the analysis brings out the interest of using surface parameters to characterize 3D surface topography obtained in 5-axis milling.

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Section: Introductionmentioning

confidence: 99%

Model for the prediction of 3D surface topography in 5-axis milling

Lavernhe

Quinsat

Lartigue

2010

Int J Adv Manuf Technol

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“…In most of the cases the part obtained after machining is not identical with the one obtained from simulation because the CAM software does not take into account the cutting tool ware, the rigidity of the machine, the workpiece clamping etc. The next step is to optimize the process considering all the elements that could influence the surface quality [8,10].…”

Section: Methodsmentioning

confidence: 99%

“…The geometric properties of the surface will be dependent upon the cutter diameter, number of cutting flutes, the cutting speed, the step-over and the feedrate -factors that were studied widely in many researches. As we saw in [8] the cutting tool trajectory also influences the quality of the part. Many CAM systems have cutting simulations that show the progress of a cutter through the material, but they are unable to reproduce the actual geometric properties on the surface of the part, because they do not treat all the elements involved in the milling process [10,8].…”

Section: Introductionmentioning

confidence: 91%

Surface quality and machining time optimization based on feedrate correction function of tool trajectories types

2017

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Original scientific paper Today, any CAM software offers some different tool trajectories strategies for milling free form geometries. In any finishing milling operation the most important objective is the surface quality. However, the CAM users must have the know-how to choose the tool trajectories according to geometry complexity, cutting tool geometry and its contact on the machined surface. The quality of the surface and machining time is influenced also by tool trajectories. Research results presented in this paper are focused on determination of a correction factor for cutting parameters based on tool trajectories type. To validate experimental correction factor, optimum feed rates are calculated for each type of trajectories based on surface quality and machining time analysis for inclined surfaces. The finishing procedures are made with a ball end milling tool. Keywords: cutting parameters; machining time; milling; surface roughness; tool trajectory Optimizacija kvalitete površine i vremena obrade na osnovu korekcije brzine posmaka putanje alataIzvorni znanstveni članak Danas svaki CAM program nudi različite strategije putanje alata za glodanje geometrije slobodnih oblika. Svaka završna operacija glodanja usmjerena je kvaliteti površine. Ipak, korisnici CAM-a moraju znati kako odabrati putanju alata u skladu sa složenošću geometrije, geometrijom alata i njegovim dodirom s obrađivanom površinom. Na kvalitetu površine te vrijeme obrade djeluje i putanja alata. Rezultati ovog istraživanja usmjereni su određivanju faktora korekcije parametara rezanja na osnovu vrste putanje alata. U svrhu provjere eksperimentalnog faktora korekcije, izračunate su optimalne brzine posmaka za svaki tip putanje na temelju kvalitete površine i analize vremena obrade za kose površine. Završni postupci obrade načinjeni su alatom za glodanje s kuglastom glavom.

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“…The authors developed a generalized analytical model that took into account the toolworkpiece orientation angle, as well as the cutting path in predicting the profile of the machined surface. Liu et al [13] used the solid geometry of endmilling cutters to predict the effect of cutter geometry and machining parameters on the quality of endmilled surfaces. The surface topography was predicted based on the geometry of the tool's cutting flutes, and good results were obtained when feed and speed were incorporated into the model.…”

Section: Endmilling Surface Generationmentioning

confidence: 99%

“…The aim of this paper is to identify simple strategies which yield a large improvement in the surface finish, and for this purpose our simple model is adequate. The more exhaustive surface generation models [13][14][15], while being more accurate, are computationally intensive and can be challenging to apply in real-time analysis and visualization. Past work on changing the tool-workpiece engagement angle [9,16,17] has focused on ensuring a constant chip load on the tool during machining.…”

Section: Endmilling Surface Generationmentioning

confidence: 99%

Improving endmilling surface finish by workpiece rotation and adaptive toolpath spacing

Vijayaraghavan

Hoover

Hartnett

et al. 2009

International Journal of Machine Tools and Manufacture

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a b s t r a c tFree-form surfaces are being used in a growing number of engineering applications, especially in injection molding of consumer products. Decreasing the manufacturing cost and time of these molds will improve the efficiency of manufacturing injection molded consumer products. This paper is motivated by the need for simple strategies to improve the quality of and decrease the time required to machine free-form surfaces. We present two methods to improve the surface finish of parts finished with ball-nose endmilling. In the first method the surface finish is improved by finding an optimal orientation angle for the workpiece relative to the machining axis. In the second method finish is improved by adaptively varying the step-size when using raster toolpaths. The adaptive variation is controlled by a user-defined finish improvement factor, where the spacing density is increased only if the improvement in surface finish is greater than the finish improvement factor. These methods are implemented using an analytical model of the workpiece surface finish based on the mean scallop height of the machined surface. Results from the analytical model are verified with machining experiments, and we show that the adaptive spacing strategy can improve the surface quality by more than 50% with a small increase in the toolpath length. To achieve a similar improvement in surface quality by uniformly decreasing the path spacing results in a much larger increase in the toolpath length. The strategies discussed in this paper allow process planners intuitive control over the toolpath layout and spacing and improve the efficiency of machining high quality parts.

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Surface finish visualisation in high speed, ball nose milling applications

Cited by 38 publications

References 8 publications

Model for the prediction of 3D surface topography in 5-axis milling

Model for the prediction of 3D surface topography in 5-axis milling

Surface quality and machining time optimization based on feedrate correction function of tool trajectories types

Improving endmilling surface finish by workpiece rotation and adaptive toolpath spacing

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