Abstract
Cutting force prediction is very important to optimize machining parameters and monitor machining state. In order to predict cutting force of sculptured surface machining with ball end mill accurately, tool posture, cutting edge, contact state between cutter, and workpiece are studied. Firstly, an instantaneous motion model of ball end mill for sculptured surface is established. The instantaneous milling coordinate system and instantaneous tool coordinate system are defined to describe the position and orientation of tool, and the transformation matrix between coordinate systems is derived. Secondly, by solving three boundaries around engagement of cutter and workpiece, a cutter-workpiece engagement model related to tool posture, milling parameters, and tool path is established. It has good adaptability to the variable tool axis relative to the machining surface. Finally, an algorithm of thickness about an instantaneous undeformed chip is researched, and a prediction model of cutting force is realized with microelement cutting theory. Also, the model is suitable for sculptured surface machining with arbitrary tool posture and feed direction. The accuracy of the proposed prediction model was verified by a series of experiments.
Highlights
Ball end mill is an important milling tool
It has good adaptability to surface machining due to the normal orientation of the spherical contour surface pointing to full space
As an important physical parameter, cutting force directly or indirectly affects wear and deformation of tool, machining efficiency, etc. It is an effective indicator for monitoring the machining process [1]. e evident feature of ball end milling for sculptured surface is that the contact condition between the tool and workpiece varies along the tool path
Summary
Ball end mill is an important milling tool. It has good adaptability to surface machining due to the normal orientation of the spherical contour surface pointing to full space. (1) A modeling method for the CWE of sculptured surface milling is proposed, which considers the tool axis vector and feed direction (2) A projection dimensionality method is used to simplify the solving process of the instantaneous engage section between the cutting edge and the workpiece (3) e parameterized expression of the undeformed chip thickness is improved, and it could be applied to the variable axis machining for the sculptured surface e rest of the paper is organized as follows: in Section 2, the motion model of the tool is established and the MCS is defined. Numerous literatures show that the solid model has very high accuracy. erefore, the results of the solid model are YM Cutter
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
