Abstract
The traditional analytical cutting force prediction method for ball-end milling ignores the effect of the inclination angle on cutting forces. In this paper, a new experimental method for cutting force prediction methods considering the inclination angle in the ball-end milling process is proposed. First, the actual immersion ranges of cutter in the ball-end milling process with and without an inclination angle are analyzed by a geometrical method and the cutting force prediction model with an inclination angle is developed by a numerical integration method. Second, considering that entry and exit angles of cutting zones for different cutter layers vary due to the inclination angle, a milling force coefficients identification approach for different cutter layers is established by experimental calibration. Comparing the traditional analytical cutting force prediction method that ignores the inclination angle, the numerical simulation results show that the prediction force values calculated by the proposed method have a better consistency with the measured values.
Highlights
With normal vector self-adaptability, ball-end milling cutters are extensively used in machining parts with sculptured surfaces in the aerospace and motor industries [1,2,3] such as an aircraft engine blade, an integral impeller, and more
In the ball-end milling process, the contact interface between the cutter and work piece is constantly changing, which results in the changes of the cutting force, cutter wear state, vibration, machining precision, and more
Feng et al [6,7] established a nonlinear local cutting force model in the form of power function based on an approximate cutting edge equation and gave a cutting force model of ball-end milling cutter with runout
Summary
With normal vector self-adaptability, ball-end milling cutters are extensively used in machining parts with sculptured surfaces in the aerospace and motor industries [1,2,3] such as an aircraft engine blade, an integral impeller, and more. In the ball-end milling process, the contact interface between the cutter and work piece is constantly changing, which results in the changes of the cutting force, cutter wear state, vibration, machining precision, and more. Cutting force modeling is the basis of modeling and analysis of ball end cutter milling process especially for a milling process analysis and cutting force prediction. Yucesan and Altintas [9] analyzed the spherical geometric characteristics of the ball-end cutting edge and calculated the cutting force through pressure and friction forces on the rake face and flank face of the cutter. In order to improve the milling process, some researchers [10,11] focus on minimizing cutting forces and vibrations by adjusting the inclination angle. A cutting force computational model based on the Altintas [12] milling force model is proposed by analyzing cutter entry and exit angles of cutting elements in different cutting states and validity of the model is verified by simulation and experiment
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