Velocity effect sensitivity analysis of ball-end milling Ti-6Al-4 V

• Published in: International journal of advanced manufacturing technology Vol. 118; no. 11-12; pp. 3963 - 3982
• Main Authors: Zhang, Anshan, Liu, Xianli, Yue, Caixu, Li, Rongyi, Liang, Steven Y., Wang, Lihui
• Format: Journal Article
• Language: English
• Published: London Springer London 01-02-2022; Springer Nature B.V
• Subjects: Ball end milling; Ball milling; Ball-end cutter; CAE) and Design; Computer-Aided Engineering (CAD; Critical point; Cutting parameters; Cutting speed; Die/mold; Direction selection; End milling cutters; Engineering; Feed direction; Feed direction selection; Inclination angle; Industrial and Production Engineering; Machine tools; Machined surface quality; Mechanical Engineering; Media Management; Milling (machining); Original Article; Plowing; Sensitivity analysis; Surface properties; Titanium; Velocity; Velocity effect; Velocity effects; Ball-end milling; Feed direction selection; Velocity effect; Plowing
• ISSN: 0268-3768; 1433-3015; 1433-3015
• DOI: 10.1007/s00170-021-08049-4

Ball-end cutters are widely used in industries of dies, molds, and aerospace, which have the problem of poor machined surface quality due to the low cutting speed near the tool-tip. With the increase in the complexity of parts, it will become more and more difficult to avoid the tool-tip participating in the cutting. In this paper, the velocity effect sensitivity of the ball-end cutter is analyzed, and several key positions, including the intersection points of the CWE boundaries, are selected to describe the cutting speed in three dimensions. The relationships between the cutting speed of the critical points and important variables such as the machining inclination angle and the feed direction were investigated. The optimal range of feed direction is obtained when the tool-tip engages in the contact circle. The core aim of the feed direction selection is to make the tool engagement area in a high position by changing the feed direction, to avoid surface damage and improve the quality of the machined surface. Finally, an experimental study was carried out, and the results corroborate the effectiveness of the selection method. In the experiment, it was also found that cutting-out from the cutter contact position can improve the surface quality in the directions of non-optimal range, and the milling force and chips shape will vary with the change of the feed direction.