Force modeling and applications of inclined ball end milling of micro-dimpled surfaces

Graham, Eldon; Park, C. I.; Park, S. S.

doi:10.1007/s00170-013-5310-5

Cited by 14 publications

(6 citation statements)

References 24 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…In this study, it can be especially observed in the y direction force. Factors as additional frictional forces on the flank face of the cutting edges due to elastic recovery of material, geometric non-uniformity in the cutting tool, cutter run-out, and eccentricity may cause less material to be removed in this direction compared with the x and y direction forces, also affecting the depth between successive dimples and contributing to the difference between measured and analytical forces [10,18]. It is also important to mention that the cutting and edge coefficients need to be identified for different machining setups, tools, and workpieces: mechanistic models can be highly accurate [16].…”

Section: Forces Exhibited By Flat End Mill During Machiningmentioning

confidence: 99%

“…The micromilling technique significantly reduces the time needed to fabricate dimpled surfaces by creating a row of dimples in a single pass of the cutter. Many other machining methods are not efficient by comparison, as individual dimples are made through repeated horizontal and vertical movements of the cutting tool; thus, pattern surfaces from inclined micro-milling exhibit improved tribological properties [10].…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Directional friction surfaces through asymmetrically shaped dimpled surfaces patterned using inclined flat end milling

Resendiz

Graham

Egberts

et al. 2015

Tribology International

View full text Add to dashboard Cite

Section: Forces Exhibited By Flat End Mill During Machiningmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Directional friction surfaces through asymmetrically shaped dimpled surfaces patterned using inclined flat end milling

Resendiz

Graham

Egberts

et al. 2015

Tribology International

View full text Add to dashboard Cite

“…Methods for calculating milling stability were first developed for cylindrical tools in the context of 3-axis milling due to the simpler geometry of the process, and some authors generalize those approaches to 5-axis milling. However, these methods can only be used for some specific cases of 5-axis milling [6][7][8][9]. There are two major differences between these specific 5-axis cylindrical milling operations and the general five-axis ball milling that complicate stability calculations.…”

Section: Introductionmentioning

confidence: 99%

Chatter-free milling strategy of a slender Blisk blade via stock distribution optimization and continuous spindle speed change

Petráček

Falta

Stejskal

et al. 2022

Int J Adv Manuf Technol

View full text Add to dashboard Cite

The machining process of Blisk blades poses multiple challenges due to high requirements on surface quality and precision combined with high dynamic compliance of the thin-walled blades. Avoidance of chatter is thus of high priority in Blisk blade machining. However, the geometry of the Blisk blade array where the tool must fit between individual blades significantly limits the possibilities of controlling stability through the relative orientation of the tool and workpiece. Thus, the main parameters that can be used to control the stability of the process are the distribution of stock allowance and the spindle speed. Due to the effect of material removal on the blade’s dynamic properties, spindle speed needs to be adjusted throughout the machining process to keep it within the continuously changing stability gaps. This paper describes in detail an optimization procedure for the design of stock allowance distribution in such a way that a continuous spindle speed modulation is possible that avoids chatter throughout the machining process by maintaining spindle speeds within stability gaps. The presented algorithm uses finite element analysis software to simulate the effects of stock allowance distribution and material removal on workpiece dynamical properties. This information is then coupled with a stability model based on the Jacobian of the cutting force with respect to the regenerative deflection to identify the varying stability gaps throughout the machining process. The proposed method was experimentally verified.

show abstract

“…There are many approaches based on trigonometric relationships which work well in cylindrical mills, but due to the geometric complexity of the problem, the calculations or cutting force models are too specific to be useful in general 5-ax milling stability calculations, e.g. Wojciechowski et al [7], Graham et al [8], Hao [9], Tsai [10],Shtehin [11] or Lazoglu [12]. For this reason, it is often advantageous to use simulation software to calculate tool-workpiece engagement, as e.g.…”

Section: Introductionmentioning

confidence: 99%

An analytical formulation of ZOA-based machining stability for complex tool geometries: application to 5-axis ball-end milling

Falta

Sulitka

Zeman

2022

Int J Adv Manuf Technol

View full text Add to dashboard Cite

The paper describes a computationally convenient analytical formulation of the stability of the cutting process with respect to self-excited vibrations in the case of five-axis milling based on the commonly used zero-order approximation. In the case of five-axis milling with general milling cutters, it is difficult to calculate stable machining process conditions for two main reasons. The first reason is the difficulty of calculating the mean value of the cutting force Jacobian with respect to the regenerative displacement (closely related to a milling directional matrix) for a generally inclined tool, and the second reason is the nonlinearity of this Jacobian with respect to the process parameters, which means that the problem cannot be reduced to a linear eigenvalue problem as is usual for linear cases (e.g. cylindrical milling with respect to the axial depth of cut). In the first part, this paper presents a modification of the calculation of the machining stability limits for a nonlinearly dependent cutting force Jaco-

show abstract

Force modeling and applications of inclined ball end milling of micro-dimpled surfaces

Cited by 14 publications

References 24 publications

Directional friction surfaces through asymmetrically shaped dimpled surfaces patterned using inclined flat end milling

Directional friction surfaces through asymmetrically shaped dimpled surfaces patterned using inclined flat end milling

Chatter-free milling strategy of a slender Blisk blade via stock distribution optimization and continuous spindle speed change

An analytical formulation of ZOA-based machining stability for complex tool geometries: application to 5-axis ball-end milling

Contact Info

Product

Resources

About