Surface Quality Evaluation in the Milling Process Using a Ball Nose End Mill

Varga, Ján; Ižol, Peter; Vrabeľ, Marek; Kaščák, Ľuboš; Drbúl, Mário; Brindza, Jozef

doi:10.3390/app131810328

Cited by 7 publications

(4 citation statements)

References 54 publications

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“…The most common method to achieve this sampling is the use of contact profilometers [ 2 , 3 , 4 , 5 , 6 , 7 , 8 , 9 , 10 ] as a reliable but time-consuming method. Some other methods use the non-contact surface exploration by lasers [ 11 ], laser interferometry [ 12 , 13 ], laser confocal microscopes [ 14 ], optical systems [ 15 , 16 , 17 , 18 ], machine vision systems [ 19 ], or are inspired by research into the optical properties of surfaces (ability to split white light, diffractive properties) using scanning electron microscopy and atomic force microscopy [ 20 ].…”

Section: Introductionmentioning

confidence: 99%

A Study of 2D Roughness Periodical Profiles on a Flat Surface Generated by Milling with a Ball Nose End Mill

Horodinca,

Chifan,

Paduraru

et al. 2024

Materials

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This paper presents a study of 2D roughness profiles on a flat surface generated on a steel workpiece by ball nose end milling with linear equidistant tool paths (pick-intervals). The exploration of the milled surface with a surface roughness tester (on the pick and feed directions) produces 2D roughness profiles that usually have periodic evolutions. These evolutions can be considered as time-dependent signals, which can be described as a sum of sinusoidal components (the wavelength of each component is considered as a period). In order to obtain a good approximate description of these sinusoidal components, two suitable signal processing techniques are used in this work: the first technique provides a direct mathematical (analytical) description and is based on computer-aided curve (signal) fitting (more accurate); the second technique (synthetic, less accurate, providing an indirect and incomplete description) is based on the spectrum generated by fast Fourier transform. This study can be seen as a way to better understand the interaction between the tool and the workpiece or to achieve a mathematical characterisation of the machined surface microgeometry in terms of roughness (e.g., its description as a collection of closely spaced 2D roughness profiles) and to characterise the workpiece material in terms of machinability by cutting.

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Section: Introductionmentioning

confidence: 99%

A Study of 2D Roughness Periodical Profiles on a Flat Surface Generated by Milling with a Ball Nose End Mill

Horodinca,

Chifan,

Paduraru

et al. 2024

Materials

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“…The evaluation of surface roughness (parameters Sa, Ssk, and S10z) using a noncontact method when milling a complex surface on a 3-axis milling center was dealt with in research by Varga [23], who evaluated these parameters regarding the selected milling strategy. He compared the milling strategies such as constant, spiral, and spiral circle milling, while evaluating the topography of the surface at three different heights with respect to the contact of the tool with the machined surface.…”

Section: Introductionmentioning

confidence: 99%

Influence of Tool Inclination and Effective Cutting Speed on Roughness Parameters of Machined Shaped Surfaces

Varga,

Demko,

Kaščák

et al. 2024

Machines

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Free-form surfaces in the automotive or aviation industry where the future shape of the product will contain complex surfaces raises the question of how to achieve the necessary shape of the required quality in the milling process. One of the methods of their production is the use of 5-axis milling, in which it is necessary to consider not only the input data of the process itself, but also the methodology for evaluating the desired results. Correctly answered questions can thus facilitate the choice of the inclination of the tool when machining parts of the surfaces defined in the experiment. The primary goal of the paper was to monitor the influence of tool inclination on the quality of the machined surface and effective cutting speed by evaluating surface roughness and surface topography. The experiment was designed to show the effect of different tool positions while the feed per tooth fz for the finishing operation remained constant. The best result in terms of surface quality was achieved with a tool inclination of 15° in the cutting process. The most unfavorable result was obtained with a tool axis inclination of zero degrees due to unfavorable cutting conditions.

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“…Relevant studies have shown that sliding friction zones and adhesive friction zones exist between the tool and the chips during the milling of titanium alloys. Due to the low thermal conductivity of titanium alloy materials, as the cutting progresses, the temperature rises in the adhesive friction zone near the cutting edge, causing the chips to adhere to the tool surface, resulting in a decrease in milling cutter processing efficiency and quality [8][9][10]. Therefore, introducing surface micro-textures onto the tool surface reduces the effective contact area, alters the frictional state between the tool and the chips, reduces the friction coefficient on the tool surface, and improves the heat dissipation conditions of the tool surface, thereby optimizing milling performance and meeting the practical machining requirements of improving tool wear resistance and reducing the use of cutting fluid [11,12].…”

Section: Introductionmentioning

confidence: 99%

Research on the Milling Performance of Micro-Groove Ball End Mills for Titanium Alloys

Zhang,

Shi,

Wang

et al. 2024

Lubricants

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Titanium alloys are widely used in various fields, but milling titanium alloy materials often leads to problems such as high milling forces, increased milling temperatures, and chip adhesion. Thus, the machinability of titanium alloys faces challenges. To improve the milling performance of titanium alloy materials, this study analyzes the effective working area on the surface of the milling cutter through mathematical calculations. We design micro-grooves in this area to utilize their friction-reducing and wear-resisting properties to alleviate the aforementioned issues. The effective working area of the ball end milling cutter’s cutting edge is calculated based on the amount of milling and the installation position between the milling cutter and the workpiece. By observing the surface structure of seashells, micro-grooves are proposed and designed to be applied in the working area of the milling cutter surface. The impact of the micro-groove area on the milling cutter surface and spindle speed on milling performance is discussed based on milling simulation and experimental tests. Experimental results show that the cutting force, milling temperature, and chip resistance to adhesion produced by micro-groove milling cutters are superior to conventional milling cutters. Milling cutters with three micro-grooves perform best at different spindle speeds. This is because the presence of micro-grooves on the surface of the milling cutter improves the friction state, promoting a reduction in milling force, while the micro-grooves also serve as storage containers for chips, alleviating the phenomenon of chip softening and adhesion to the cutter. When conducting cutting tests with a milling cutter that has three micro-grooves, the milling force is reduced by 10% to 30%, the milling temperature drops by 10% to 20%, and the surface roughness decreases by 8% to 12%.

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Surface Quality Evaluation in the Milling Process Using a Ball Nose End Mill

Cited by 7 publications

References 54 publications

A Study of 2D Roughness Periodical Profiles on a Flat Surface Generated by Milling with a Ball Nose End Mill

A Study of 2D Roughness Periodical Profiles on a Flat Surface Generated by Milling with a Ball Nose End Mill

Influence of Tool Inclination and Effective Cutting Speed on Roughness Parameters of Machined Shaped Surfaces

Research on the Milling Performance of Micro-Groove Ball End Mills for Titanium Alloys

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