Journal of Mechanical Engineering >

2017 , Vol. 53 >Issue 1: 198 - 205

DOI: https://doi.org/10.3901/JME.2017.01.198

A Semi-analytical Cutter Workpiece Engagement Model for Ball End Milling of Sculptured Surface

  • WEI Zhaocheng ,
  • WANG Minjie ,
  • WANG Xuewen ,
  • ZHAO Danyang
Expand
  • 1. Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education， Dalian University of Technology， Dalian 116024;
    2. TKAS Auto Steel Co.， Ltd.， Dalian 116600

Online published: 2017-01-05

Fold

Abstract

Cutter workpiece engagement (CWE), which defines the interaction region between tool and workpiece, is the basis for studying mechanics and dynamics of cutting. In sculptured surface machining, the CWE usually appears irregular geometry and varies along curve path. A semi-analytical CWE model for multi-axis ball end milling of sculptured surface is presented. With the ideas of differential and rigid-body rotation transformation, general sculptured surface machining is considered as a combination of some small inclined plane machining, and the CWE of inclined plane machining can be obtained by rotating that of horizontal plane machining. By taking the cutting allowance material as a combination of some thin parallel slices, an analytical CWE model for ball end milling of horizontal plane is proposed. And thus the CWE model for multi-axis ball end milling of sculptured surface machining is obtained. The precision and efficiency of proposed model are investigated by some simulation examples. Simulation results reveal that the developed model can describe CWE in multi-axis ball end milling of sculptured surfaces with high precision and efficiency.

 

Key words： cutter workpiece engagement; sculptured surface machining; ball end mill

Cite this article

WEI Zhaocheng , WANG Minjie , WANG Xuewen , ZHAO Danyang . A Semi-analytical Cutter Workpiece Engagement Model for Ball End Milling of Sculptured Surface[J]. Journal of Mechanical Engineering, 2017 , 53(1) : 198 -205 . DOI: 10.3901/JME.2017.01.198

References

 [1]  IMANI B M, SADEGHI M H, ELBESTAWI M A. An improved process simulation system for ball-end milling of sculptured surfaces [J]. Int. J. Mach. Tools Manuf., 1998, 38(9)：1089-1107.

 [2]  倪其民, 李从心, 阮雪榆. 基于实体造型的球头铣刀三维铣削力仿真 [J]. 上海交通大学学报, 2001, 35(7)：1003-1007.

        NI Qimin, LI Congxin, RUAN Xueyu. Cutting forces simulation of ball-end milling based on solid modeling [J]. Journal of Shanghai Jiao Tong University, 2001, 35(7)：1003-1007.

 [3]  YANG Yun, ZHANG Weihong, WAN Min, et al. A solid trimming method to extract cutter–workpiece engagement maps for multi-axis milling [J]. Int. J. Mach. Tools Manuf., 2013, 68(9-12)：2801-2813.

 [4]  KIM G M, CHO P J, CHU C N. Cutting force prediction of sculptured surface ball-end milling using Z-map [J]. Int. J. Mach. Tools Manuf., 2000, 40(2)：277-291.

 [5]  KIM G M, KIM B H, CHU C N. Estimation of cutter deflection and form error in ball-end milling processes [J]. Int. J. Mach. Tools Manuf., 2003, 43(9)：917-924.

 [6]  LAZOGLU I. Sculpture surface machining: A generalized model of ball-end milling force system [J]. Int. J. Mach. Tools Manuf., 2003, 43(5)：453-462.

 [7]  张臣, 周儒荣, 庄海军, 等. 基于Z-map模型的球头铣刀铣削力建模与仿真 [J]. 航空学报, 2006, 27(2)：347-352.

        ZHANG Chen, ZHOU Rurong, ZHUANG Haijun, et al, Modeling and simulation of ball end milling force based on z-map model [J]. Acta Aeronautica et Astronautica Sinica, 2006, 27(2)：347-352.

 [8]  WEI Zhaocheng, WANG Minjie, CAI Yujun, et al. Prediction of cutting force in ball-end milling of sculptured surface using improved Z-map [J]. Int. J. Adv. Manuf. Technol., 2013, 68(5-8)：1167-1177.

 [9]  WEI Zhaocheng, WANG Minjie, ZHU Jianning, et al. Cutting force prediction in ball end milling of sculptured surface with Z-level contouring tool path [J]. International Journal of Machine Tools and Manufacture, 2011, 51(5)：428-432.

[10]  OZTURK B, LAZOGLU I. Machining of free-form surfaces. Part I: Analytical chip load [J]. Int. J. Mach. Tools Manuf., 2006, 46(7-8)：728-735.

[11]  OZTURK B., LAZOGLUI., ERDIM H., Machining of free-form surfaces. Part II: Calibration and forces [J]. Int. J. Mach. Tools Manuf., 2006, 46(7-8)：736-746.

Options
Outlines

/

〈 〉

　 Copyright © Journal of Mechanical Engineering, All Rights Reserved.
Powered by Beijing Magtech Co. Ltd,.