Investigating the cutting phenomena in free-form milling using a ball-end cutting tool for die and mold manufacturing

• Published in: International journal of advanced manufacturing technology Vol. 71; no. 9-12; pp. 1565 - 1577
• Main Authors: de Souza, Adriano Fagali, Diniz, Anselmo Eduardo, Rodrigues, Alessandro Roger, Coelho, Reginaldo Teixeira
• Format: Journal Article
• Language: English
• Published: London Springer London 01-04-2014; Springer Nature B.V
• Subjects: CAE) and Design; Carbide tools; Chip formation; Computer-Aided Engineering (CAD; Curvature; Cutting force; Cutting speed; Cutting tools; Engineering; Free form; Industrial and Production Engineering; Machine tools; Machining centres; Mechanical Engineering; Media Management; Milling (machining); Original Article; Plastic deformation; Shearing; Surface properties; Surface roughness; Workpieces; Effective tool radius; Free-form milling; Ball-end tool; Tool-surface contact; Cutting force
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-013-5579-4

This paper presents an investigation of nonplanar tool-workpiece interactions in free-form milling using a ball-end cutting tool, a technique that is widely applied in the manufacturing of dies and molds. The influence of the cutting speed on the cutting forces, surface quality of the workpiece, and chip formation was evaluated by considering the specific alterations of the contact between tool-surface along the cutting time. A trigonometric equation was developed for identifying the tool-workpiece contact along the toolpath and the point where the tool tip leaves the contact with the workpiece. The experimental validation was carried out in a machining center using a carbide ball-end cutting tool and a workpiece of AISI P20 steel. The experimental results demonstrated the negative effect of the engagement of the tool tip into the cut on machining performance. The length of this engagement depends on the tool and workpiece curvature radii and stock material. When the tool tip center is in the cut region, the material is removed by shearing together with plastic deformation. Such conditions increase the cutting force and surface roughness and lead to an unstable machining process, what was also confirmed by the chips collected.