Study on Analysis of Cutting Mechanism of Ball End Mill for Concave and Convex Spherical Surface Using 3D-CAD

Abstract

In this paper, cutting mechanism and cutting performance of ball end mill for spherical surface with contour path method is investigated. Ball end mills are used to produce molds, dies and so on. However, the edge shape is complex, so cutting process is not clear. Then, it is not clear effectively using method of the tool based on good cutting performance. Therefore, in this study, the purpose is proposal of high efficient and high accurate cutting method is using 5-axis control machine tool. At first, cutting model assembled by a ball end mill (R8 mm) and a workpiece with convex or concave spherical surface (Workpiece radius 20 mm) is carried out using 3D-CAD (SolidWorks). The pick feed direction which is from bottom to top is defined “Stepped up”, the one which is inverse direction is defined “Stepped down”. In addition, both cutting methods include up milling and down milling, then there are four cutting modes. The radius of tool path for contour path are varied from 14.0 mm to 19.4 mm for convex spherical surface, from 6.5 to 9.2 mm for concave spherical surface. The lead angle of the tool is defined the plus sign when the tool is inclined to the tool feed direction and varied from-45° to 45°. Secondly, the cutting cross-sectional area is calculated by the interference of a rake surface of the tool and an uncut chip volume which can be removed by one cutting operation. Thirdly, cutting experiments are done in order to measure cutting force. Finally, analytical and experimental results are discussed, and then the cutting conditions which are expected good cutting performance are considered.