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

Souza, Adriano Fagali de; Diniz, Anselmo Eduardo; Rodrigues, Alessandro Roger; Coelho, Reginaldo Teixeira

doi:10.1007/s00170-013-5579-4

Cited by 42 publications

(24 citation statements)

References 18 publications

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“…These free forms are commonly machined by ball end nose cutting tools as the cutter readily adapts well to the curvatures [22]. However, the tip of these tools has a negative effect on performance machining, due to the zero value of cutting speed at this point [23,24].…”

Section: Scientific Motivationsmentioning

confidence: 99%

Simple Discriminatory Methodology for Wear Analysis of Cutting Tools: Impact on Work Piece Surface Morphology in Case of Differently Milled Kinetics Steel H13

et al. 2020

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Recently, there is growing interest in optimisation of finishing process thanks to the technologies to follow online the wear of cutting tools. In the present paper, one of the cheapest and simplest non-contact methodologies is described in detail and investigated with robustness evaluation. To simulate the finishing operation of a die, in this study, two cavities were designed in AISI H13 steel. Different inserts corresponding to PVD-(Ti,Al)N coated cemented carbide tool were tested. The described methodology is easy to be applied in manufacturing cutting machining with the opportunity to be implemented on machining processes to follow reasonably wear process of cutting tools.

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Section: Scientific Motivationsmentioning

confidence: 99%

Simple Discriminatory Methodology for Wear Analysis of Cutting Tools: Impact on Work Piece Surface Morphology in Case of Differently Milled Kinetics Steel H13

et al. 2020

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“…For roughness evaluation, first it might be considered that in free-form milling, besides by the conventional machining conditions, the roughness is also affected by the alteration of the tool-surface contact and also by the feed rate oscillation. The feed oscillation alters the tool load, than the tool deflection, which damage the surface roughness [27]. CAM A generated the second fastest NC file, but the worst on roughness.…”

Section: Surface Roughnessmentioning

confidence: 99%

Study of tool paths calculated by different commercial CAM systems and influences on the real machining time and surface roughness for milling free-form geometries

Souza

Käsemodel

Arias³

et al. 2019

J Braz. Soc. Mech. Sci. Eng.

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Today, there are many commercial CAM systems available capable of generating NC codes for milling free-form geometries up to 5-axis. However, the quality of these NC codes has not yet been well discussed so far. Apparently, on the computer screen and the geometrical simulation provided by CAM, tool paths calculated by different CAM systems seem to be the same. However, as observed in this work, NC codes differ expressively according to the CAM software applied, and it affects the productivity and quality of the machined surface. Thus, a study was carried out to investigate this issue. A representative workpiece with free-form geometries was designed; a data acquisition system from an open architecture CNC was developed and NC codes were generated by five worldwide commercial CAM systems. The finishing milling operation was evaluated. The results presented difference of up to 30% on the real machining time, differences in the feed rate oscillation and up to 2 times the surface roughness value. This work reveals an essential limitation on the CAM algorithm and arises a new point for benchmarking CAM systems, which brings an opportunity to improve the calculation of tool paths for milling free-form geometries.

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“…Fan [1] investigates the changing of cutting speed in 3-axis ball-end milling and points out that the cutting speed is the speed factor that influences machined surface quality and tool life. de Souza et al [2] show the effect of the working diameter in chip removal, cutting force and surface roughness, where higher cutting speed decreases the surface roughness. Wojciechowski et al [3] analyses ball-end milling in the case of different tool inclination that results in different working diameters.…”

Section: Introductionmentioning

confidence: 99%

A geometric approach of working tool diameter in 3-axis ball-end milling

Mikó

Zentay

2019

Int J Adv Manuf Technol

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When machining free-form surfaces with a ball-end milling tool, the working tool diameter is constantly changing even if the tool path is constant. The reason is that the surface normal of the milled surface is continuously changing along the milling path. When the working diameter is changing, the cutting parameters also change. This variation effects the roughness homogeneity of the smoothed surface. Simultaneous five-axis milling solves this problem; however, the price and complexity of this technology can be a problem for some industrial sectors. In the paper, the geometrical background of a solution to this problem is presented for a 3-axis ball-end milling process for machining a free form surface. The paper provides the deduction of the theory by the use of homogeneous transformations. The geometrical problem of the cutting process is treated locally where the general machined surface is substituted at every point by its tangent plane. From the result of the presented method, a milling strategy can be formulated for ball-end milling that minimises the change in the momentary working diameter thus providing a more constant cutting parameter.

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

Cited by 42 publications

References 18 publications

Simple Discriminatory Methodology for Wear Analysis of Cutting Tools: Impact on Work Piece Surface Morphology in Case of Differently Milled Kinetics Steel H13

Simple Discriminatory Methodology for Wear Analysis of Cutting Tools: Impact on Work Piece Surface Morphology in Case of Differently Milled Kinetics Steel H13

Study of tool paths calculated by different commercial CAM systems and influences on the real machining time and surface roughness for milling free-form geometries

A geometric approach of working tool diameter in 3-axis ball-end milling

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