Cutting force prediction in ball end milling of sculptured surface with Z-level contouring tool path

• Published in: International journal of machine tools & manufacture Vol. 51; no. 5; pp. 428 - 432
• Main Authors: Wei, Z.C., Wang, M.J., Zhu, J.N., Gu, L.Y.
• Format: Journal Article
• Language: English
• Published: Kidlington Elsevier Ltd 01-05-2011; Elsevier
• Subjects: Applied sciences; Ball end milling; Contouring; Cutters; Cutting; Cutting force; End milling cutters; Exact sciences and technology; Feed turning angle; Mathematical models; Mechanical engineering. Machine design; Sculptured surface machining; Turning; Turning (machining); Z-map; Sculptured surface machining; Z-map; Feed turning angle; Ball end milling; Cutting force; Force measurement; Free form; Chip formation; Machining; Turning; Contact angle; Experimental study; Modeling; Steady state; Three axis machine; Optimal trajectory; Milling; Feeder; Cutting tool; Reliability; Machine tool spindle
• ISSN: 0890-6955; 1879-2170
• DOI: 10.1016/j.ijmachtools.2011.01.011

This paper presents an approach to predict cutting force in 3-axis ball end milling of sculptured surface with
Z-level contouring tool path. The variable feed turning angle is proposed to denote the angular position of feed direction within tool axis perpendicular plane. In order to precisely describe the variation of feed turning angle and cutter engagement, the whole process of sculptured surface milling is discretized at intervals of feed per tooth along tool path. Each segmented process is considered as a small steady-state cutting. For each segmented cutting, the feed turning angle is determined according to the position of its start/end points, and the cutter engagement is obtained using a new efficient
Z-map method. Both the chip thickness model and cutting force model for steady-state machining are improved for involving the effect of varying feed turning angle and cutter engagement in sculptured surface machining. In validation experiment, a practical 3-axis ball end milling of sculptured surface with
Z-level contouring tool path is operated. Comparisons of the predicted cutting forces and the measurements show the reliability of the proposed approach.