Papers by Keyword: Ball-End Milling Cutter

Abstract: In this paper, influence mechanism of variously physical factors for milling force in any feed direction is studied during the milling process. Firstly, the effects of spindle eccentricity, cutter deflection and cutter vibration for the instantaneously undeformed cutting thickness are analyzed, and the mathematical expressions of chip thickness is set up. Then,on this basis of cutting force and chip load, the milling force model of ball-end mill with considering integrated physical factors is established though the differential method, and a simulation system for prediction of milling forces during the milling process is developed. This milling force model is verified through simulation and analysis of milling forces.

Abstract: In high speed milling hardened steel, cutting performance of cutter is uncertainty because hardness distribution and machining elements change. Based on the experiments of high speed milling hardened steel, the interaction among cutting force, cutting temperature, cutting vibration, processing surface quality and machining efficiency is investigated by means of interpretative structural modeling method, hierarchical structure model in high speed milling hardened steel is founded, optimization design method of high speed milling performance is proposed. Results show that uneven distribution of hardness swells the interaction of machining elements, and causes cutting vibration and processing surface quality mutations. Hierarchical structure model reveals the relationship between control variables and performance index in high speed milling hardened steel, it helps optimization of process parameters, restrains cutting vibration in high speed milling automobile mould, and improves processing surface quality and machining efficiency.

Abstract: Modeling and simulation of ball-end milling cutter has an important means in studying milling process characteristics. Most scholars ignore practicability analysis before modeling, according to this, modeling and simulation of optimization path is proposed based on cutting path optimization experiment in this paper, which simplifies modeling and simulation and makes model development and practical application have more pertinence and practicality.

Abstract: For the instability of ball-end milling cutter in high speed milling, instantaneous cutting process of high speed milling hardened steel was studied. The model of instantaneous cutting layer parameters of high speed ball-end cutter was established, and the influence of cutting speed and inclination angles on instantaneous cutting layer parameters were obtained. Using the model, instantaneous cutting force was studied, and high speed milling experiment was processed. Results show that the increase of cutting speed makes the change rate of cutting layer parameters increasing, leads to the energy concentration in cutting process, and increases the impact on milling cutter. The increase of inclination angle makes the instantaneous cutting layer parameters show a trend of decrease and the decrease of cutting thickness more rapidly, which caused instantaneous unit cutting force to increase and the instantaneous main cutting force appears increasing trend, and the cutting process become unstable.

Abstract: In order to depress cutter vibration caused by high hardness and periodic change of cutting force in high speed milling complex surface, investigated the modal characteristics of ball-end milling cutter through the modal analysis and transient analysis. Using the models of dynamic cutting force and cutting vibration, acquired dynamics characteristics of high speed ball-end milling cutter by the spectrum analysis of dynamic cutting force, simulation analysis of cutting vibration and experiment of high speed milling hardened steel. Results indicate that high speed ball-end milling energy concentrates in few special frequencies, the rotational speed and the numbers of cutter teeth determine the fundamental frequency. High speed ball-end milling cutter easily makes radial bending vibration by the lower modal characteristics, the overhang and inclination angle of cutter affect its dynamics characteristics significantly, and the modal parameters and vibration model of cutter acquired by step response method have higher credibility.

Abstract: On the basis of the ball-end milling feature during high-speed machining impeller, the relationship between cutting force and chips is analyzed in this paper. The model of ball-end milling cutter cutting force is founded through differential method. And the coefficients solution of cutting force model is expounded. Besides, the coefficients solution and the cutting force model simulation are implemented by the software Matlab.

Abstract: In this paper, a new mathematical model and modeling method of ball-end milling cutter which satisfies the request of physical simulation in virtual NC machining system are proposed. The accurate expressions of the cutting edge are presented. The precise functional surface model of ball-end cutter is developed. And the 3-D visualization for ball-end milling cutter in virtual NC machining is implemented. The model can provide necessary and accurate geometric information for physical simulation and has been applied in milling force simulation. It laid the foundation for integration of geometric simulation and physical simulation.

Abstract: The strategies of selection of feedrate are studied in the ball-end machining process. The optimization algorithm utilizes the objective requirements of a line of NC program to set constraints relation between cutting force and feedrate and optimizes feedrate by controlling the variety ranges of the instantaneous cutting force specified in the cutting forces simulation. Off-line feedrate optimization software for complex sculptured is developed. For a line of NC program, the developed software calculates instantaneous cutting force and an optimization algorithm is used to acquire desired feedrate. The machining experimental results show that the proposed algorithms are satisfying in reduction of machining time and improvement of machining quality.

Abstract: In this paper, a new mathematical model and grinding method of ball-end milling cutter are proposed, based on the orthogonal spiral cutting edge curve. The movements of grinding wheel and ball-end milling cutter are presented while grinding rake face. In order to grind conveniently and avoid interference, a conical wheel is also designed and employed to grind the rake face of ball-end milling cutter on a grinder. In order to improve the machining characteristics of ball-end milling cutter, the model of rake face with equal rake angle is established. The software of ball-end milling cutter is developed to design and optimize different shapes of rake face. Furthermore, the simulation analysis on rake face with equal rake angle is carried out to confirm the validation of the mathematical models.

Abstract: According to the principle producing the cutting track of cutter, to study the influence of the cutting track of cutter on the process of high speed ball-end milling, the single-factor models for evaluating the cutting track of cutter are established. Adopting four kinds of the typical cutting track of cutter, the experiment of high speed ball-end milling is processed. The model of multi-ply fuzzy comprehensive evaluation for the cutting track of cutter is established, fuzzy comprehensive evaluation for the cutting track of high speed ball-end milling cutter is accomplished by the application of fuzzy mathematics theory. Results show that the cutting contact curve of cutter affects directly the process of high speed ball-end milling, fuzzy and uncertain properties exist in the evaluation for the cutting track of cutter. The optimum cutting track can be selected by multi-ply fuzzy comprehensive evaluation for the cutting track of high speed ball-end milling cutter.