Surface topography in ball-end milling processes as a function of feed per tooth and radial depth of cut

Buj-Corral, Irene; Calvet, Joan Vivancos; Domínguez-Fernández, Alejandro

doi:10.1016/j.ijmachtools.2011.10.006

Cited by 86 publications

(43 citation statements)

References 17 publications

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“…With the theoretical standpoint, it is possible to describe the texture obtained in ball-end milling [13] from numerical simulations. Recent works have shown that the surface topography can be simulated by taking into account cutting conditions (transversal step and the feedrate) [14] but also the evolution of the tool axis orientation in 5-axis milling [15]. Fig.…”

Section: Surface Topography Modelingmentioning

confidence: 99%

Mold Manufacturing Optimization: A Global Approach of Milling and Polishing Processes

et al. 2015

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Within the context of molds and dies production, frequent changes in design and increased competitiveness require an overall optimized manufacturing process. The finishing process is typically composed of an accurate milling stage to manage shape deviations, followed by polishing operations to reach required surface roughness. Local improvements of milling and polishing set independently do not necessarily lead to an optimal manufacturing process planning. This study aims to propose a method to improve the whole sequence of milling and polishing considering constraints from polishing process and machine tool. The turning point between milling and polishing operations consists in linking them by the evaluation of the surface topography obtained after milling. From there, thanks to a predictive model of surface roughness, the design of polishing operations can be performed, and polishing time evaluated. On the other hand, for a given machine tool and a desired intermediate surface topography, milling parameters for finishing can also be modified and actual machining time predicted. Thus the whole process is evaluated balancing the milling and polishing times to reduce the total manufacturing time. Experiments are carried out on an aluminum mold for blowing process of plastic bottles.

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Section: Surface Topography Modelingmentioning

confidence: 99%

Mold Manufacturing Optimization: A Global Approach of Milling and Polishing Processes

et al. 2015

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“…Buj-Corral et al 16 presented the influence of feed, eccentricity and helix angle on surface roughness for side milling operations with cylindrical tools. Buj-Corral et al 17 developed a numerical model to predict topography and surface roughness in ball-end milling processes based on geometric tool-workpiece intersection. The proposed model allows determining surface topography as a function of feed per tooth and revolution, radial depth of cut, axial depth of cut, number of teeth, tool teeth radii, helix angle, eccentricity and phase angle between teeth.…”

Section: Introductionmentioning

confidence: 99%

Simultaneous prediction of surface topography and surface location error in milling

Yuan

Zeng

Chen

2014

Proceedings of the Institution of Mechanical Engineers, Part C:

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The machined surface topography, surface roughness and surface location error are very important evaluation indexes for machining quality, which directly affect the performance characteristics of the machined workpiece. In this paper, a new model of the arbitrary point of the cutter edge with respect to the arbitrary frame of the machining feature point is built. The proposed model incorporates the surface location error into the relative motion of the cutter with respect to the workpiece using the harmonic balance methods. Further, a nonlinear programming problem is proposed to obtain the scallop value of an arbitrary point on the nominal machined surface. Since the obtained scallop value of each point can be used for constructing the topography of the machined surface as well as calculating the surface roughness, the proposed model can simultaneously predict the surface topography, surface roughness and surface location error.Simulations and experiments indicate that feed per tooth, runout and number of cutter teeth are vital factors influencing the topology of the machined surface. The surface location error of the cutter due to the number of cutter teeth is an essential factor that influences the parallelism or perpendicularity of the machining feature. The effectiveness and feasibility of the proposed method is verified by a machining example.

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“…In addition, poor surface roughness can also occur in the narrow and unstable cutting region near the periphery of the tool. Buj-Corral et al [9] developed a numerical model that predicts the topography and surface roughness in ball-end milling processes. The results show that using a low feed rate generates a very good surface roughness in the longitudinal direction.…”

Section: Introductionmentioning

confidence: 99%

Integrated optimization using mixture design to confirm the finishing of AISI P20 using different cutting strategies and ball nose end mills

et al. 2014

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Surface topography in ball-end milling processes as a function of feed per tooth and radial depth of cut

Cited by 86 publications

References 17 publications

Mold Manufacturing Optimization: A Global Approach of Milling and Polishing Processes

Mold Manufacturing Optimization: A Global Approach of Milling and Polishing Processes

Simultaneous prediction of surface topography and surface location error in milling

Integrated optimization using mixture design to confirm the finishing of AISI P20 using different cutting strategies and ball nose end mills

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