共查询到20条相似文献,搜索用时 15 毫秒
1.
Yi Lu Yoshimi Takeuchi Ichiro Takahashi Masahiro Anzai 《The International Journal of Advanced Manufacturing Technology》2005,25(7-8):628-646
The purpose of this paper is to provide a reasonable means to approach tool shape optimization of ball end mill for high-speed milling operation. The paper presents a new development of an integrated system for ball end mill design, creation and evaluation that is more flexible and more systematic than the commercially available tool fabrication systems.The study consists of three major contents: (1) 3D-CAD/CAM system development for ball end mill design and creation, (2) fundamental investigations of cutting characteristics with different ball end mills, and (3) improvement of tool life and machining stabilization for high-speed milling by means of new tool shape proposals. These are explained in the following sections, respectively. Through the above developments and investigations, it is evidently found that the developed system shows great validity and possibility to realize tool shape optimization of the ball end mill. 相似文献
2.
Il-Hae Kim 《Journal of Mechanical Science and Technology》2008,22(5):914-923
In this paper, a 4-electrode cylindrical capacitance displacement sensor (CCDS) is presented as an indirect force sensor for
a high speed milling spindle. A rotor-bar system for the magnetic exciter is designed to investigate the tool deflection with
respect to the applied cutting force. To extract the deflection signal from the CCDS, the dynamic orbital motion at each rotating
speed of spindle is predetermined and then subtracted from the CCDS signal. The CCDS signal is also used as a reference sync
signal. The rotor-bar system is designed so that the rotor affects the tool-spindle dynamics only as an added mass but does
not contribute to the bending property. The additional effect of the rotor mass in the exciter setup is compensated for by
an experimental modeling. The cutting force can be estimated by using modified CCDS signals and FRF. Cutting experiments are
conducted to show reliable performances of the proposed approach by high speed machining applications. 相似文献
3.
Ik Soo Kang Jeong Suk Kim Yong Wie Seo 《Journal of Mechanical Science and Technology》2008,22(2):293-299
The analysis of the cutting force in micro end milling plays an important role in characterizing the cutting process, as the
tool wear and surface texture depend on the cutting forces. Because the depth of cut is larger than the tool edge radius in
conventional cutting, the effect of the tool edge radius can be ignored. However, in micro cutting, this radius has an influence
on the cutting mechanism. In this study, an analytical cutting force model for micro end milling is proposed for predicting
the cutting forces. The cutting force model, which considers the edge radius of the micro end mill, is simulated. The validity
is investigated through the newly developed tool dynamometer for the micro end milling process. The predicted cutting forces
were consistent with the experimental results. 相似文献
4.
5.
6.
The cutting tool wear degrades the quality of the product in the manufacturing process, for this reason an on-line monitoring of the cutting tool wear level is very necessary to prevent any deterioration. Unfortunately there is no direct manner to measure the cutting tool wear on-line. Consequently we must adopt an indirect method where wear will be estimated from the measurement of one or more physical parameters appearing during the machining process such as the cutting force, the vibrations, or the acoustic emission, etc. The main objective of this work is to establish a relationship between the acquired signals variation and the tool wear in high speed milling process; so an experimental setup was carried out using a horizontal high speed milling machine. Thus, the cutting forces were measured by means of a dynamometer whereas; the tool wear was measured in an off-line manner using a binocular microscope. Furthermore, we analysed cutting force signatures during milling operation throughout the tool life. This analysis was based on both temporal and frequential signal processing techniques in order to extract the relevant indicators of cutting tool state. Our results have shown that the variation of the variance and the first harmonic amplitudes were linked to the flank wear evolution. These parameters show the best behavior of the tool wear state while providing relevant information of this later. 相似文献
7.
In high-speed ball end milling, cutting forces influence machinability, dimensional accuracy, tool failure, tool deflection, machine tool chatter, vibration, etc. Thus, an accurate prediction of cutting forces before actual machining is essential for a good insight into the process to produce good quality machined parts. In this article, an attempt has been made to determine specific cutting force coefficients in ball end milling based on a linear mechanistic model at a higher range of rotational speeds. The force coefficients have been determined based on average cutting force. Cutting force in one revolution of the cutter was recorded to avoid the cutter run-out condition (radial). Milling experiments have been conducted on aluminum alloy of grade Al2014-T6 at different spindle speeds and feeds. Thus, the dependence of specific cutting force coefficients on cutting speeds has been studied and analyzed. It is found that specific cutting force coefficients change with change in rotational speed while keeping other cutting parameters unchanged. Hence, simulated cutting forces at higher range of rotational speed might have considerable errors if specific cutting force coefficients evaluated at lower rotational speed are used. The specific cutting force coefficients obtained analytically have been validated through experiments. 相似文献
8.
Machine tool chatter is a serious problem which deteriorates surface quality of machined parts and increases tool wear, noise, and even causes tool failure. In the present paper, machine tool chatter has been studied and a stability lobe diagram (SLD) has been developed for a two degrees of freedom system to identify stable and unstable zones using zeroth order approximation method. A dynamic cutting force model has been modeled in tangential and radial directions using regenerative uncut chip thickness. Uncut chip thickness has been modeled using trochoidal path traced by the cutting edge of the tool. Dynamic cutting force coefficients have been determined based on the average force method. Several experiments have been performed at different feed rates and axial depths of cut to determine the dynamic cutting force coefficients and have been used for predicting SLD. Several other experiments have been performed to validate the feasibility and effectiveness of the developed SLD. It is found that the proposed method is quite efficient in predicting the SLD. The cutting forces in stable and unstable cutting zone are in well agreement with the experimental cutting forces. 相似文献
9.
Prediction of cutting forces and machining error in ball end milling of curved surfaces -I theoretical analysis 总被引:1,自引:0,他引:1
Bernard W. Ikua Hisataka Tanaka Fumio Obata Satoshi Sakamoto 《Precision Engineering》2001,25(4):266-273
This paper presents a theoretical model by which cutting forces and machining error in ball end milling of curved surfaces can be predicted. The actual trochoidal paths of the cutting edges are considered in the evaluation of the chip geometry. The cutting forces are evaluated based on the theory of oblique cutting. The machining errors resulting from force induced tool deflections are calculated at various parts of the machined surface. The influences of various cutting conditions, cutting styles and cutting modes on cutting forces and machining error are investigated. The results of this study show that in contouring, the cutting force component which influences the machining error decreases with increase in milling position angle; while in ramping, the two force components which influence machining error are hardly affected by the milling position angle. It is further seen that in contouring, down cross-feed yields higher accuracy than up cross-feed, while in ramping, right cross-feed yields higher accuracy than left cross-feed. The machining error generally decreases with increase in milling position angle. 相似文献
10.
Tool wear monitoring is a popular research topic in the field of ultra-precision machining. However, there appears to have been no research on the monitoring of tool wear in ultra-precision raster milling (UPRM) by using cutting chips. In the present research, monitoring tool wear was firstly conducted in UPRM by using cutting chips. During the cutting process, the fracture wear of the diamond tool is directly imprinted on the cutting chip surface as a group of ‘ridges’. Through inspection of the locations, cross-sectional shape of these ridges by a 3D scanning electron microscope, the virtual cutting edge of the diamond tool under fracture wear is built up. A mathematical model was established to predict the virtual cutting edge with two geometric elements: semi-circle and isosceles triangle used to approximate the cross-sectional shape of ridges. Since the theoretical prediction of cutting edge profile concurs with the inspected one, the proposed tool wear monitoring method is found to be effective. 相似文献
11.
12.
13.
A geometrical model of the cut in five-axis milling accounting for the influence of tool orientation 总被引:3,自引:3,他引:0
E. Agson Gani J. P. Kruth P. Vanherck B. Lauwers 《The International Journal of Advanced Manufacturing Technology》1997,13(10):677-684
This paper presents a model of the cut geometry in five-axis milling. This allows the establishment of a better model of cutting force to account for the influence of the tool orientation. The formulation of the width and the thickness of the cut were derived and implemented in a computer simulation. The results of simulations were verified experimentally and a good agreement was obtained. The result shows the importance of including the influence of the tool orientation in the cut cross-section calculation. 相似文献
14.
15.
16.
G. Poulachon M. Dessoly C. Le Calvez J. L. Lebrun V. Prunet I. S. Jawahir 《Wear》2001,250(1-12):334-343
Experimental results have shown that the machinability of tool steels, in term of tool-life, is increased with sulphides addition. It seems that this increase depends on cutting speed, probably due to the existence of an adherent layer of manganese sulphides (MnS) frequently observed in turning. Previous studies on the same materials have shown that at high cutting speeds, the action of sulphur disappears. The choice of the best cutting parameters is presented in detail according to the tool-work material pair method. Experimental design has been used to determine the tool-wear rate and to discuss the effect of each influencing factor and interaction. During the progressive tool-wear, rake face investigations to study the influence of sulphide inclusions have been performed using scanning electron microscopy (SEM) techniques. 相似文献
17.
18.
Z. C. Wei M. L. Guo M. J. Wang S. Q. Li J. Wang 《Machining Science and Technology》2013,17(5):688-711
AbstractThe force prediction is the precondition of improving equipment utilization ratio and optimizing process for CNC machining. Cutter-workpiece engagement (CWE) and in-cut cutting edge (ICCE) are the keys. In this article, a new analytic method of CWE and ICCE is proposed for ball end milling of sculptured surface and the prediction model of milling force is established. The sculptured surface is discretized into a series of infinitesimal inclined planes corresponding to cutter location points. The geometry relationships of cutter axis, feed direction and inclined plane are defined parametrically. The boundary curves and the boundary inflection points of the CWE are obtained by intersecting spatial standard curved surfaces with rotation transformation of coordinate system. The effective intersection points of the CWE and the cutter edge curve in Xc-Yctwo-dimensional plane are the upper and lower boundary points of ICCE. Based on the instantaneous chip thickness considering arbitrary feed direction, the force prediction model for ball end mill of three-axis surface milling is established. Simulation and experiment show that CWE and ICCE calculated by analytic method are well consistent with those of solid method. The predicted cutting forces match well with the measurements both in magnitude and variation trend. 相似文献
19.
This study was carried out to understand micro-milling of aluminum material with ball nose end mill and consisted of four stages: experimental work, modelling, mono and multi objective optimization. In the first stage (experimental work), micro-milling experiments were carried out using Taguchi method. The effects of spindle speed, feed per tooth and depth of cut on tool wear, force and surface roughness were investigated. Cutting tools and workpiece surfaces were also inspected via scanning electron microscope. Adhesion and abrasion wear mechanisms during micro-milling of aluminum were observed. Workpiece surfaces had the accumulations of plastically deformed workpiece material due to the high ductility of aluminum. In the second stage (modelling), all data gathered in the experimental works were utilized to formulate first-order models with interaction. These first-order models with interaction could be used to predict responses in micro-milling of aluminum with a minor error. In the third stage (mono-objective optimization), responses were used alone in optimization study as an objective function. To minimize all responses, Taguchi’s signal to noise ratio was used. The effect of control factors on responses was determined by analysis of variance. In the fourth stage (multi objective optimization), responses were optimized simultaneously using grey relational analysis. 相似文献
20.
Bernard W. Ikua Hisataka Tanaka Fumio Obata Satoshi Sakamoto Takeyasu Kishi Tatsuo Ishii 《Precision Engineering》2002,26(1):821
This paper presents the results of a series of experiments performed to examine the validity of a theoretical model for evaluation of cutting forces and machining error in ball end milling of curved surfaces. The experiments are carried out at various cutting conditions, for both contouring and ramping of convex and concave surfaces. A high precision machining center is used in the cutting tests. In contouring, the machining error is measured with an electric micrometer, while in ramping it is measured on a 3-coordinate measuring machine. The results show that in contouring, the cutting force component that influences the machining error decreases with an increase in milling position angle, while in ramping, the two force components that influence the machining error are hardly affected by the milling position angle. Moreover, in contouring, high machining accuracy is achieved in “Up cross-feed, Up cut” and “Down cross-feed, Down cut” modes, while in ramping, high machining accuracy is achieved in “Left cross-feed, Downward cut” and “Right cross-feed, Upward cut” modes. The theoretical and experimental results show reasonably good agreement. 相似文献