Investigation of lead and tilt angle effects in 5-axis ball-end milling processes

Öztürk, Erdem; Tunç, Lütfi; Budak, Erhan

doi:10.1016/j.ijmachtools.2009.07.013

Cited by 154 publications

(76 citation statements)

References 11 publications

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“…3). Prowadzi to z kolei do zmiennego odkształcenia sprężystego narzędzia oraz przedmiotu obrabianego, czego skutkiem może być niedokładność wymiarowo -kształtowa [3,4,5,6]. Dokładność wykonania powierzchni opływowych łopatek turbin ma wpływ na trwałość i niezawodność całej turbiny.…”

Section: Rys 1 Rodzaje Powierzchni Złożonych O Promieniach Krzywiznunclassified

Effect of toroidal cutter axis orientation on the cutting forces in the five-axis machining of sculptured surface turbine blade of INCONEL 718

et al. 2015

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StreszczeniePrzedstawiono wyniki badań składowych sił skrawania podczas procesu symultanicznego 5-osiowego frezowania powierzchni złożonych frezem toroidalnym. Przedmiotem badań była wklęsła oraz wypukła powierzchnia łopatki turbiny ze stopu INCONEL 718. Orientacja osi narzędzia określana jest względem wektora normalnego powierzchni poprzez programowanie kątów wyprzedzenia lub/i pochylenia. Określono wpływ 5-osiowych parametrów orientacji osi narzędzia oraz zmiennego promienia krzywizny na siły skrawania. Słowa kluczowe: symultaniczne 5-osiowe frezowanie, siły skrawania, powierzchnie złożone EFFECT OF TOROIDAL CUTTER AXIS ORIENTATION ON THE CUTTING FORCES IN THE FIVE-AXIS MACHINING OF SCULPTURED SURFACE TURBINE BLADE OF INCONEL 718Abstract Conducted measurement cutting force components during simultaneous five-axis milling of sculptured surfaces using toroidal cutter. Subject of research was concave and convex surface of the turbine blade of INCONEL 718. The tool axis orientation was determined relative to the surface normal vector by programming lead and / or tilt angle. Based on the obtained the results of research defined the effect of five-axis parameters toroidal cutter orientation and a variable radius of curvature on the cutting forces.

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Section: Rys 1 Rodzaje Powierzchni Złożonych O Promieniach Krzywiznunclassified

Effect of toroidal cutter axis orientation on the cutting forces in the five-axis machining of sculptured surface turbine blade of INCONEL 718

et al. 2015

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“…For ball-end milling, effects of lead angle on cutting forces were predicted through simulations using the process model drawn by Ozturk and Budak [15]. While Ozturk and Tunc presented the detailed analysis of lead and tilt angle's effects on cutting forces, torque, form errors and stability [16]. Also researches that dealt with the effects of tool-surface inclination on ball end mill cutting forces were conducted by using thermomechanical modeling of oblique cutting [17,18].…”

Section: Advances In Mechanical Engineeringmentioning

confidence: 99%

Prediction and Experimental Validation of Cutting Force for Bull-Nose End Mills with Lead Angle

Gao

Luo

et al. 2014

Advances in Mechanical Engineering

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This study focuses on cutting force predictions with the tool-workpiece inclination angle in bull-nose milling based on the semimechanistic force model. By analyzing kinematics and mechanics of the bull-nose end mills during cutting, force expressions including lead angle are stated and the model is exerted on each discrete element as oblique cutting with coordinate transformation and numerical integration to obtain the dynamic cutting force components. An improved identification method considering speed variations along the tool axis is applied to calibrate coefficients. Coefficients are regarded as the function of each elemental elevation. Then, a geometry-based method to acquire cutter workpiece engagement (CWE) is proposed. Also acquisition of accurate start and exit angles on each slice is deliberated elaborately for cutters with lead or tilt angle in milling processes. Thereby, to verify the validity of the force prediction model and start-exit angle acquisition method, experiments with variable lead angles are conducted under different axial immersions. The results reveal that the presented model and approaches can predict cutting forces with high accuracy. Finally, the cutting force components under different cutter postures and conditions are analyzed to provide instructions for parameter selections.

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“…Notably, Kim et al [32] introduced a different concept and proposed to use the cutter feed direction to determine the undeformed chip thickness for non-horizontal cuts. As for the much more complex rotational ball-end milling cuts (due to the continuously changing cutter feed direction), only the cutter surface normal direction has been applied to the determination of the undeformed chip thickness [33,34].…”

Section: Undeformed Chip Thickness Determination Directionmentioning

confidence: 99%

Cutting force prediction for ball-end mills with non-horizontal and rotational cutting motions

Azeem

Feng

2012

Int J Adv Manuf Technol

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Accurate cutting force prediction is essential to precision machining operations as cutting force is a process variable that directly relates to machining quality and efficiency. This paper presents an improved mechanistic cutting force model for multi-axis ball-end milling. Multi-axis ballend milling is mainly used for sculptured surface machining where non-horizontal (upward and downward) and rotational cutting tool motions are common. Unlike the existing research studies, the present work attempts to explicitly consider the effect of the 3D cutting motions of the ballend mill on the cutting forces. The main feature of the present work is thus the proposed generalized concept of characterizing the undeformed chip thickness for 3D cutter movements. The proposed concept evaluates the undeformed chip thickness of an engaged cutting element in the principal normal direction of its 3D trochoidal trajectory. This concept is unique and it leads to the first cutting force model that specifically applies to non-horizontal and rotational cutting tool motions. The resulting cutting force model has been validated experimentally with extensive verification test cuts consisting of horizontal, non-horizontal, and rotational cutting motions of a ball-end mill.

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Investigation of lead and tilt angle effects in 5-axis ball-end milling processes

Cited by 154 publications

References 11 publications

Effect of toroidal cutter axis orientation on the cutting forces in the five-axis machining of sculptured surface turbine blade of INCONEL 718

Effect of toroidal cutter axis orientation on the cutting forces in the five-axis machining of sculptured surface turbine blade of INCONEL 718

Prediction and Experimental Validation of Cutting Force for Bull-Nose End Mills with Lead Angle

Cutting force prediction for ball-end mills with non-horizontal and rotational cutting motions

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