Abstract
In milling with a ball end mill using a 5-axis machining center, the attitude of tool or workpiece is controlled by tilting two axes, therefore allowing milling to be performed by a cutting edge of an outer portion, which has a large cutting speed. However, the effects of the tool tilting angle on the cutting forces, tool deflection and machining error have not been clearly identified. In this 1st report, geometric quantities such as the tool-workpiece contact region, undeformed chip thickness along the cutting edge and the area of cutting cross-section, and the cutting speed in slot milling with tool tilted by one or two axes are analyzed, and variations of these quantities with the tool tilting angle are discussed. A cutting model proposed in previous papers, in which a cutting edge of both a spherical portion and a cylindrical portion engage with the workpiece, is applied to the above milling process. Cutting forces in various tool tilting angles are predicted, and compared with experimental results. Predicted results are in good agreement with experimental results. It is found that when a large positive angle is specified for each of the tool tilting angles, the variation of cutting forces in milling decreases, and it also becomes possible to obtain a large cutting speed.
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