Micro-textured Ball-end Milling Research Articles

Study on cutting performance of micro-textured ball-end milling cutter with multiple distribution density under the action of cutting edge

Study on cutting performance of micro-textured ball-end milling cutter with multiple distribution density under the action of cutting edge

Optimising milled titanium alloy concave surface quality with micro-textured ball-end milling cutters

Optimising milled titanium alloy concave surface quality with micro-textured ball-end milling cutters

Influence of micro-textured parameters on cutting performance and chip formation of milling Ti6Al4V

In view of the lack of researches on the influence of micro textures on the cutting performance of milling cutters, this paper studies the cutting performance of the micro-textured ball-end milling cutter, taking the distance from the cutting edge and the offset angle as the influencing factors, and through the comparative test with non-texture cutters, studies the cutting performance and formation of the chip. The results showed that when micro textures are close to the cutting edge, the milling force is larger, while the offset angle had no significant effects on the milling force. The optimized micro-textured parameters are 120 µm and 0.3°. Compared with the non-texture cutter, the micro-textured cutter had better effects of anti-wear and anti-friction, as well as surface quality of the workpiece. The deformation is more serious when the chip passes the rake face. This paper has some guiding significance for the preliminary design of micro-textured cutters.

Precision distribution design of micro-textured ball-end milling tool and the analysis of its effects on the strength of the insert

Most prior studies have not carried out a precise theoretical analysis and design of micro textures and have thus only conducted experimental analyses of cutting performance that lack theoretical analysis and reliability. This study thus first determined the specific micro-textured application area from a theoretical point of view, based on the contact relationship between the rake face and the chip. Secondly, the micro-textured distribution laws were determined for this area along with a definition of the distribution boundaries of the micro textures. Thirdly, the influence of cutting depth on the number of micro-textured rows and columns was analyzed, and these optimized numbers were thus obtained. Finally, the influence of the micro-textured distribution on the strength of the insert was simulated and analyzed. The results showed that the application of micro textures had no significant effect on the strength of the tool. The results of the research ensured consistency for subsequent research into the milling performance of micro-textured ball-end milling tools.

Study on mechanical properties of titanium alloy with micro-texture ball-end milling cutter under different cutting edges

When precision cutting titanium alloy, the cutting part of cutting tool is mainly concentrated in the cutting edge area, so there is a strong emphasis upon the cutting edge’s geometric parameters. Studies have found that putting a micro-texture on the cutting surface can reduce the cutting force. This article looks at the milling force involved in cutting titanium alloy with a micro-textured ball-end milling cutter with different shaped cutting edges. First, a milling model relating to different cutting edges is established based on the traditional model of milling force. Then, the effects of different cutting edge geometry parameters and micro-texture parameters on milling force are simulated and tested using a finite element method. With milling force serving as the evaluation index, the optimum micro-texture parameters for a blunt circular cutting edge are a micro-pit diameter of 40 μm, a distance between micro-pits of 175 μm, a distance from the cutting edge of 110 μm, and a blunt circle radius of 60 μm. For a negative chamfer edge, the optimum parameters were a micro-pit diameter of 50 μm, a distance between micro-pits of 175 μm, a distance from the cutting edge of 120 μm, an edge width of 200 μm, and an edge angle of 10°.

Thermo-mechanical coupling behaviour when milling titanium alloy with micro-textured ball-end cutters

The high-speed milling of titanium alloy is a very complex nonlinear dynamic cutting process, and there are mutual coupling effects between multiple physical fields of the tool. Therefore, the thermo-mechanical coupling behavior of micro-textured ball-end milling cutters during the cutting of titanium alloy was studied in depth, combined with theoretical calculations, milling experiments and simulation analysis. First, based on the experimental data of milling titanium alloy, the stress field of the micro-textured ball-end milling cutter was solved. Then, the dimensional method was used to solve the temperature field of the micro-textured ball-end milling cutter. Finally, the thermo-mechanical coupling simulation analysis of the micro-textured ball-end milling cutter was carried out, and the stress concentration area and tool breakage area of the micro-textured ball-end milling cutter under the thermo-mechanical coupling effect are obtained. This in turn gives a theoretical basis for further improving the performance and tool life of micro-textured cutters.

Optimizing milled titanium alloy concave surface quality with micro-textured ball-end milling cutters

The cutting speed at the lowest point of a ball-end milling cutter is zero, which results in poor workpiece surface quality and serious cutter wear. To alleviate this problem, a micro-texture can be processed on the rake face of a ball-end milling cutter to provide an anti-friction and anti-wear mechanism. The objective of the work reported here is to reduce cutter wear and optimise workpiece surface quality. By using a mathematical model of row spacing to analyse the differential geometric relationship between cutters and surfaces at their contact point, we have been able to obtain optimal cutter orientation. This was verified by simulating concave surface machining. Experiments were then conducted to verify the approach and the results showed that when the cutter orientation is adjusted to its optimum, the surface quality of the workpiece processed by a micro-textured ball-end milling cutter is at its best. [Submitted 10 May 2018; Accepted 28 July 2019]

Optimization of Texture Density Distribution of Carbide Alloy Micro-Textured Ball-End Milling Cutter Based on Stress Field

The insertion of micro-textures plays a role in reducing friction and increasing wear resistance of the cutters, which also has a certain impact on the stress field of the cutter during milling. Therefore, in order to study the mechanisms of friction reduction and wear resistance of micro-textured cutters in high speed cutting of titanium alloys, the dynamic characteristics of the instantaneous stress field during the machining of titanium alloys with micro-textured cutters were studied by changing the distribution density of the micro-textures on the cutter. First, the micro-texture insertion area of the ball-end milling cutter was theoretically analyzed. Then, variable density micro-textured ball-end milling cutters and non-texture cutters were used to cut titanium alloy, and the mathematical model of milling force and cutter-chip contact area was established. Then, the stress density functions of different micro-texture density cutters and non-texture cutters were established to simulate the stress fields of variable density micro-textured ball-end milling cutters and non-texture cutters. Finally, the genetic algorithm was used to optimize the variable density distribution of micro-textured cutters in which the instantaneous stress field of the cutters was taken as the optimization objective. The optimal solution for the variable density distribution of the micro-textured cutter in the cutter-chip tight contact area was obtained as follows: the texture distribution densities in the first, second, and third areas are second, and third areas are 0.0905, 0.0712, and 0.0493, respectively.

Study on Milling Temperature of Titanium Alloy with Micro-Textured Ball End Milling Cutter under Radius of Blunt Edge

A high temperature is produced in the process of precision milling of titanium alloy, and the cutting temperature can be effectively reduced by placing a micro-texture on the tool surface. In order to study the milling temperature of micro-textured ball-end milling cutter in milling titanium alloy under the combined action of a blunt radius with different edges and a micro-texture with different parameters, a new method based on micro-element theory and the generation and transmission of cutting heat has been established. At the same time, the influence of different radii of blunt edges on the milling temperature is simulated by the finite element method and experimentally verified to explore the influence of different radii of a blunt edge and micro-texture parameters on the milling temperature. Taking the milling temperature as the evaluation index, the optimum parameters of micro-circular pit texture are as follows: the diameter of micro-circular pit is 40 micron, pit spacing is 225 micron, distance from cutting edge is 100 microns, and radius of the blunt edge is 60 microns.

Parameter optimization of a micro-textured ball-end milling cutter with blunt round edge

Titanium alloys is a typical difficult-to-cut material with many machining problems, build-up-edge, large cutting force, and high cutting heat. Previous research has shown that micro-texture on the tool surface can solve the above problems potentially, and that a blunt round edge of the cutting tool can enhance its strength and improve the tool wear resistance. Therefore, towards an optimal parameter of micro-texture and blunt round radius, a finite element method (FEM) simulation and an experiment are carried out, where the test result provides a set of data for a genetic algorithm–based prediction model. The optimized parameter combinations of the micro-textured ball-end milling cutter with a blunt round edge are obtained and compared in a set of experiments. The optimized parameters refer to a 40-μm radius of the blunt round edge, a 40-μm micro-texture diameter, a 175-μm spacing, a 120-μm distance from the cutting edge, and an 80-μm depth.

Anti-Friction and Anti-Wear Mechanisms of Micro Textures and Optimal Area Proportion in the End Milling of Ti6Al4V Alloy

To solve the problems of low efficiency, poor surface quality, and short tool life in the milling of titanium alloys, this study took the micro-textured ball-end milling tool as a starting point and established a platform for friction and wear tests. Based on a new method of external friction theory, the anti-friction and anti-wear mechanisms of the micro-textured tool were analyzed. According to these mechanisms, the optimal area proportion of the micro textures in the contact area between the chip and tool was theoretically investigated considering the milling force, and the proportion was verified experimentally. This work provides a reference for improving the cutting performance of hard metal tools.

Investigation on the stress field of milling titanium alloys with micro-textured ball-end milling cutter

In the milling of titanium alloy, the distribution of milling force and its related law of change seriously affect the physical properties of workpiece materials, the stress distribution on a cutter’s rake face and the interaction between the workpiece, the cutter and the chip. This article reports on a study of the stress field distribution under the conditions of anti-friction and anti-wear when cutting titanium alloy with a micro-textured ball-end milling cutter. Milling test data were used to establish empirical models of milling force and the contact area between the cutter and the chip. Based on this, the force density function of the cutter coordinate system was obtained and the equivalent stress and displacement of the cutter were simulated and analyzed. This in turn provided the means to acquire the instantaneous stress and strain relating to the cutter at any time. Analysis of the simulation results shows that the position in which the stress and strain are concentrated on the cutter is consistent with actual processing. This confirms the accuracy of the force density function and provides the basis for further study of thermo-mechanical coupling behaviors when engaged in using micro-textured ball-end milling cutters for the cutting of titanium.

Temperature Field of Tool Engaged Cutting Zone for Milling of Titanium Alloy with Ball-End Milling.

When milling titanium alloy, the cutting temperature has a strong impact on the degree of tool wear and, in turn, tool life and the surface quality of the workpiece. The distribution of the temperature field on a tool’s rake face can be improved through the use of micro-textures, which help to reduce friction and, ultimately, wear on the tool. In this paper we present a new way to measure cutting temperature and examine heat distribution when milling titanium alloy with micro-textured ball-end milling tools. We first establish the heat flux density function for the contact area between the workpiece and the tool and then for the rest of the tool. Thermal stress simulation shows that adhesive wear tends to happen in the contact area and on the flank face, rather than at the tip of the tool, with the temperature distribution gradient for the rest of the tool being more uniform. The maximum value for thermal stress on the cutting edge was 2.0782 × 106 Pa. This decrease as you move away from the cutting edge along the contact area between the tool and the workpiece. Maximum deformation of the tool is also mainly concentrated at the principal contact point, with a value of 1.9445 × 10−9 m. This, too, decreases as you move away from the cutting edge and into the rest of the contact area. This research provides the basis for the optimization of tool structure and further investigation of the thermo-mechanical coupling behavior of micro-textured ball-end milling cutters when milling titanium alloy.

A prediction model for titanium alloy surface roughness when milling with micro-textured ball-end cutters at different workpiece inclination angles

Studies have found that milling with an inclined plane when using ball-end milling cutters can reduce heating of the cutting tool. It has also been found that micro-textures on the rake face can play a role in the reduction of friction and wear. Taking these things together, milling titanium alloy with micro-textured ball-end milling cutters with workpieces at an inclined angle can have a significant influence on tool wear and the surface quality of machined workpieces. We have therefore looked at the factors affecting the quality of machined surfaces using an orthogonal test and, in particular, the effect of different micro-texture parameters and different workpiece inclination angles. Through means of an extreme difference analysis, the primary and secondary relationship between micro-texture parameters, workpiece inclination angles, and surface roughness is assessed. The analysis focuses in particular on the distance between micro-pits, micro-pit diameter, the workpiece inclination angle, the distance between the first row of micro-pits and the cutter edge, and the depth of the micro pits. On the basis of the analysis, a model that can predict surface roughness is established that provides a means of optimizing micro-textured cutter design and machining inclination angles when milling titanium alloy.