Numerical modelling of high-speed ball end milling with cutter inclination angle

Chen, X X; Zhao, Jun; Li, Y E; Han, Shiguo; Cao, Qingyuan; Li, Ang

doi:10.1177/0954405411426235

Cited by 12 publications

(3 citation statements)

References 33 publications

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“…A medium carbon steel 45 was used to produce the prototype on a DMU 40 MonoBLOCK five-axis computer numerical control (CNC) milling using ball end milling 37–40 as shown in Figure 9.…”

Section: The Machining Of the Prototypementioning

confidence: 99%

Accurate modeling of logarithmic spiral bevel gear based on the tooth flank formation and Boolean addition operation

Xiang

Xiao

2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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The logarithmic spiral bevel gear is a new type of spiral bevel gear and has received great attention in the industry for its excellent engineering characteristics. The objective of this study is to develop an accurate geometric model for the logarithmic spiral bevel gear. Based on the gear tooth flank formation mechanism, a conical logarithmic spiral curve with a constant spiral angle was constructed as the tooth trace curve. The profiles for the exterior and interior transverse of the tooth were built with an accurate involutes curve, with transition being circular arcs and straight lines. The first tooth model was established by sweeping the tooth profile accurately along the tooth trace curve, and the rest of the teeth were created by an array operation. The accurate three-dimensional model of logarithmic spiral bevel gear was finally obtained by means of a Boolean addition operation among all of the gear teeth and the root cone. An experimental study was carried out for such a gear whose number of teeth was 37, with modules being 4.5 mm, normal pressure angle being 20° and spiral angle being 35°. A DMU 40 monoBLOCK five-axis computer numerical control milling machine tool was used to produce the prototype, and a Zeiss CONTURA G3 three-dimensional coordinate instrument was employed to measure the exterior transverse addendum diameter. The linear error between the theoretical model value and the measured average value was 0.0027 mm, indicating the effectiveness and practicability of this modeling method, which provides an accurate geometric model for design and for subsequent tasks like computer-aided engineering analysis and manufacturing.

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“…A medium carbon steel 45 was used to produce the prototype on a DMU 40 MonoBLOCK five-axis computer numerical control (CNC) milling using ball end milling 37–40 as shown in Figure 9.…”

Section: The Machining Of the Prototypementioning

confidence: 99%

Accurate modeling of logarithmic spiral bevel gear based on the tooth flank formation and Boolean addition operation

Xiang

Xiao

2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Wu and Zhang 29 extended the model by including damage constitutive law in addition to the material model to define the chip separation in the milling of titanium alloy. Chen et al 30 developed a FEM for inclined ball-end milling. They utilized Cockcroft-Latham criterion for chip formation study.…”

Section: Introductionmentioning

confidence: 99%

Three-dimensional numerical modeling, simulation and experimental validation of milling of a thin-wall component

Bolar

Joshi

2017

Proceedings of the Institution of Mechanical Engineers, Part B:

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Study on mechanics of milling of thin-wall components using a helical end mill is important in view of its complex nature and prominent applications in aerospace, automobile and electronics areas. This article presents a realistic three-dimensional, thermo-structural, finite-element-based mathematical model for thin-wall milling of aerospace grade aluminum alloy. Lagrangian formulation with explicit solution scheme was employed to simulate the interaction between helical milling cutter and the workpiece. Behavior of the material at high strain, strain rate and temperature was defined by Johnson–Cook material constitutive model. Johnson–Cook damage law and friction law were used to account for chip separation and contact interaction. Experimental work was carried out to validate the results predicted by the mathematical model. The developed model predicted the forces in radial, feed and axial directions with errors of 14%, 26% and 33%, respectively. The prediction errors for deflections at top, middle and bottom portions of thin wall were within 11%–39%. The simulated chip dimensions were in good agreement with experimental results while the computed cutting temperature varied by 17% with respect to the experimental value. Overall, it was found that the developed model predicts the process responses with fair and acceptable prediction accuracy. Using the developed model, a study on the effect of process parameters on the performance parameters, namely cutting and thrust forces, stress distribution, cutting temperature, part deflection and chip morphology was carried out, which is not possible using a two-dimensional orthogonal or oblique cutting model. It was found that the developed three-dimensional mathematical model provided very useful insights into the complex physical interaction of helical cutting tool and workpiece during thin-wall milling of aerospace alloys.

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“…Micro-milling method is taken as one of the most promising methods for removing copper coating from PI substrate, 6,7 which shows several advantages such as high material removal rate, the convenience for using, the ability for processing 3D parts, 8 the low machining cost, and the unrestricted processing materials. [9][10][11][12] However, the milling force brings about several problems 13,14 and what affects processing quality most is the burr problem which not only brings about the circuit power dissipation due to the skin effect but also causes short circuit or other fatal problems. The generating mechanism and the solving means for burr in micro-milling were studied by numerous academics and research institutions.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation and processing optimization for micro-milling of copper clad polyimide

Zhao

Zhang

Gao

et al. 2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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Copper clad polyimide is becoming a significant raw material for the manufacturing of special circuits such as antennas. Micro-milling, which provides a direct and flexible fabrication method in three-dimensional product machining, has replaced traditional processing methods such as photolithography. However, severe burr problem which leads to serious power loss due to the skin effect is encountered because of the selection of improper machining strategies and parameters. In this study, the influence of machining strategy on burr formation is investigated at first. Then, the formation mechanism for different kinds of burrs in micro-milling of copper clad polyimide is analyzed. Furthermore, the burr height prediction model is established, and the optimized processing parameters are obtained through response surface methodology, the predicted burr height is 12 mm. At last, a verification experiment is conducted with the optimized processing parameters. The machining result shows that the optimized parameter combination contains spindle speed of 36,110 r/min, feed per tooth of 0.70 mm/z and tool diameter of 200 mm. The average burr height for verification test is 13.9 mm. Because of the instability of copper layer on copper clad polyimide, the actual burr height is slightly larger than theoretical prediction. The error between predicted value and experiment value is 15.8%. What is noticeable is that before optimization, the burr height is up to 100 mm, while after optimization, it reduces to 13.9 mm which is reduced by 86.1%. The achievements in this study are of great significance for optimizing machining parameters and improving machining quality and efficiency of copper clad polyimide, especially in antennas field.

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Numerical modelling of high-speed ball end milling with cutter inclination angle

Cited by 12 publications

References 33 publications

Accurate modeling of logarithmic spiral bevel gear based on the tooth flank formation and Boolean addition operation

Accurate modeling of logarithmic spiral bevel gear based on the tooth flank formation and Boolean addition operation

Three-dimensional numerical modeling, simulation and experimental validation of milling of a thin-wall component

Experimental investigation and processing optimization for micro-milling of copper clad polyimide

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