A Review of the Main Modeling Methods for Ball Nose End Milling Processes

Abstract:

The ball nose end mills are highly used for complex sculptured surfaces in 3-5 axes milling. The modeling of the cutting process using ball nose end mills is more complex than in the case of simple end mills due to the fact that the cutting speed varies continuously along the cutting edge. By tilting the cutting tool relative to the surface to be machined, the modeling is getting more complicated due to the large number of input variables. This paper presents a review of the main modeling types, underlining the specificity, the advantages and disadvantages for each type in comparison to an own research on a parametric CAD model. There are also recommendations made towards the modeling process, based on the results obtained by the authors.

• Periodical: Applied Mechanics and Materials (Volume 657)
• Pages: 93-97
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.657.93
• Online since: October 2014
• Authors: Vlad Diciuc*, Mircea Lobonțiu
• Keywords: Ball Nose End Mill, CAD Modeling Methods, Cutting Regime Parameters

References

[1] H. Iwabe, K. Shimizu and M. Sasaki, Analysis of Cutting Mechanism by Ball End Mill using 3D-CAD, JSME International Journal, Vol. 49, No. 1 (2006) 28-34.

DOI: 10.1299/jsmec.49.28

[2] K. Kikkawa, K. Nakamura and Y. Mizugaki, An Approach of Estimating Machining Error by Heuristic Geometrical Rule in 5-Axis Ball-Nosed End Milling, JSME International Journal, Vol. 47 (2004) 79-84.

DOI: 10.1299/jsmec.47.79

[3] E. Budak, E. Ozturk and L.T. Tunc, Modeling and Simulation of 5-axis Milling Processes, CIRP Annals – Manufacturing Technology, Vol. 58 (2009) 347-350.

DOI: 10.1016/j.cirp.2009.03.044

[4] N. Liu, M. Loftus and A. Whitten, Surface Finish Visualisation in High Speed, Ball Nose Milling Applications, I. J. of Machine Tools and Manufacture, Vol. 45, Issue 10 (2005) 1152-1161.

DOI: 10.1016/j.ijmachtools.2004.12.007

[5] P. Kayal, Offset Error Analysis of Ball-End Mill for Cutter-Path Generation from Point-Based Surfaces, I.J. of Advanced Manufacturing Technologies, Vol. 36 (2008) 1133-1144.

DOI: 10.1007/s00170-007-0933-z

[6] I. Lazoglu, C. Manav, and Y. Murtezaoglu, Tool Path Optimization for Free Form Surface Machining, CIRP Annals – Manufacturing Technology, Vol. 58 (2009) 101-104.

DOI: 10.1016/j.cirp.2009.03.054

[7] Y. Luo, Parametric Tool Wear Estimation Solution of HSC Appropriate Machining, I. J. of Advanced Manufacturing Technologies, Vol. 23 (2004) 546-552.

DOI: 10.1007/s00170-003-1691-1

[8] Y. Quinsat and L. Sabourin, Optimal Selection of Machining Direction for Three-Axis Milling of Sculptured Parts, International Journal of Advanced Manufacturing Technology, Vol. 27 (2006) 1132-1139.

DOI: 10.1007/s00170-004-2297-y

[9] A. Daymi, M. Boujelbene, J.M. Linares, E. Bayraktar and A. Ben Amara, Influence of Workpiece Inclination Angle on the Surface Roughness in Ball End Milling of the Titanium Alloy Ti-6Al-4V, Journal of Achievements in Materials and Manufacturing Engineering, Vol. 35 (2009).

DOI: 10.1179/026708310x12738371692932

[10] M.H. Sadeghi, H. Haghighat and M.A. Elbestawi, A Solid Modeler Based Ball-End Milling Process Simulation, International Journal of Advanced Manufacturing Technologies, Vol. 22, (2003) 775-785.

DOI: 10.1007/s00170-002-1452-6

[11] H. Terai, M. Hao, K. Kikkawa and Y. Mizugaki, Geometric Analysis of Undeformed Chip Thickness in Ball-Nosed End Milling, JSME International Journal, Vol. 47, No. 1 (2004) 2-7.

DOI: 10.1299/jsmec.47.2

[12] B.M. Imani, M.H. Sadeghi and M.A. Elbestawi, An Improved Process Simulation System for Ball-End Milling of Sculptured Surfaces, International Journal of Machine Tools & Manufacture, Vol. 38 (1998) 1089-1107.

DOI: 10.1016/s0890-6955(97)00074-6

[13] Z. Bouaziz, J.B. Younes and A. Zghal, Cost Estimation System of Dies Manufacturing based on the Complex Machining Features, International Journal of Advanced Manufacturing Technologies, Vol. 28 (2006) 262-271.

DOI: 10.1007/s00170-004-2179-3

[14] T. Umehara, K. Teramoto, T. Ishida and Y. Takeuchi, Tool Posture Determination for 5-Axis Control Machining by Area Division Method, JSME I. J., Vol. 49, No. 1 (2006) 35-42.

DOI: 10.1299/jsmec.49.35

[15] A. Warkentin, F. Ismail and S. Bedi, Comparison between Multi-Point and other 5-Axis Tool Positioning Strategies, I. J. of Machine Tools & Manufacture, Vol. 40 (2000) 185-208.

DOI: 10.1016/s0890-6955(99)00058-9

[16] G.M. Kim, B.H. Kim and C.N. Chu, Estimation of Cutter Deflection and form Error in Ball-End Milling Processes, I. J. of Machine Tools & Manufacture, Vol. 43 (2003) 917-924.

DOI: 10.1016/s0890-6955(03)00056-7

[17] Y. Lu, Y. Takeuchi, I. Takahashi and M. Anzai, An Integrated System Development for Ball End Mill Design, Creation and Evaluation, International Journal of Advanced Manufacturing Technologies, Vol. 25 (2005) 628-648.

DOI: 10.1007/s00170-004-2259-4

[18] H. Narita, L. Chen, H. Fujimoto, K. Shirase and E. Arai, Trial-Less Machining using Virtual Machining Simulator for Ball-End Mill Operation, Japan Society of Mechanical Engineers International Journal, Serie C, Vol. 49, No. 1 (2006) 50-55.

DOI: 10.1299/jsmec.49.50

[19] N. Cofaru, S. Borza, I. Rotaru, CATD of Man Processes using CNC Lathes, Annals of Oradea University. Fascicle of Management and Technological Engineering, VIII (XVIII) (2009) 1029-1034.