Predictive force model for ball-end milling and experimental validation with a wavelike form machining test

Fontaine, Michaël; Devillez, Arnaud; Moufki, Abdelhadi; Dudzinski, D.

doi:10.1016/j.ijmachtools.2005.05.011

Cited by 78 publications

(36 citation statements)

References 25 publications

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“…In this section, the main tool engagement conditions in three axes milling are analysed from the cutting forces curves measured and calculated with our analytical model using a rigid description of the tool engagement and firstly proposed in Fontaine et al [12] [32]. Discussions in this section focus mainly on the transverse force x F and feed force y F .…”

Section: Cutting Configurations In Millingmentioning

confidence: 99%

“…Only one model mixed these developments with a thermo-mechanical description of local cutting process with the purpose to enhance the understanding of milling cutting process, Fontaine et al [12] validate strong hypotheses associated to oblique cutting and propose a more predictive approach. This model uses the shear band model developed for high speed machining by Molinari et al [13] and Dudzinski et al [14] and the analytical modelling of the 3D oblique cutting configuration developed by Moufki et al [15].…”

Section: Introductionmentioning

confidence: 99%

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Experimental investigations from conventional to high speed milling on a 304-L stainless steel

Maurel-Pantel

Fontaine

Guerbet

et al. 2013

Int J Adv Manuf Technol

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Last years analytical or finite element models of milling become more efficient and focus on more physical aspects, nevertheless the milling process is still experimentally unknown on a wide range of use. This paper propose to analyse with accuracy milling operations by investigating the cutting forces values, shape of cutting forces curves obtained for different cutting speeds, and related phenomena as tool wear or tool run-out. These detailed experimental data in milling constitute a suitable experimental basis available to develop predictive machining modelling. All the tests have been conducted on the 304L stainless steel in many cutting configurations and for different tool geometries. The machinability of the 304L stainless steel with different tools geometries and configurations in shoulder milling is defined by three working zones: a conventional zone permitting stable cutting (low cutting speed; under 200-250 m.min -1 ), a dead zone (unfavourable for cutting forces level and cutting stability; between 250 and 450 m.min -1 ), and a high speed machining zone (high cutting speed; up to 450-500 m.min -1 ). All the used criteria (cutting forces, chips, wear) confirm the existence of these different zones and a correlation is proposed with cutting perturbations as run-out, cutting instability, ploughing and abrasive wear.

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Section: Cutting Configurations In Millingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Experimental investigations from conventional to high speed milling on a 304-L stainless steel

Maurel-Pantel

Fontaine

Guerbet

et al. 2013

Int J Adv Manuf Technol

Self Cite

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show abstract

“…Horizontal ball-end milling only has very limited applications as ball-end mills are often used in three-or multi-axis sculptured surface machining, where non-horizontal and/or rotational cutting motions are common. For non-horizontal ball-end milling cuts, researchers have consistently applied one of the two existing directions: cutter surface normal direction [25][26][27][28] and horizontal direction [29][30][31]. Nonetheless, these two directions, as originally proposed for horizontal cuts, may not characterize non-horizontal and rotational cuts correctly.…”

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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“…Некоторые аналитические модели были ранее предложены Merchant [7], разрабо-таны Oxley [8,9,10], последние работы были адаптированы для процессов фрезе-рования [11].…”

Section: Introductionunclassified

Formation of a model of rheological properties of hard-to-machine materials in the process of intensive cutting force deflection

Khaimovich

Balaykin

Galkina

2015

VESTNIK of Samara University. Aerospace and Mechanical Engineer

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Вестник Самарского государственного аэрокосмического университетаПовышение эффективности высокоскоростной обработки (ВСО) требует углублённого изучения физических явлений, сопровождающих процесс резания. Основными отличиями ВСО от традиционной механической обработки с физической точки зрения являются преобладание быстротекущих динамиче-ских процессов как в зоне резания, так и в системе «станок -приспособление -инструмент -изделие» и ярко выраженная нелинейность законов развития этих процессов. В этой связи исследование физических явлений, сопровождающих процесс ВСО, и установление их взаимосвязи с устойчивостью процесса ре-зания и качеством обработанной поверхности является актуальной задачей. В статье рассмотрена мето-дика определения параметров реологических свойств материала титанового сплава ВТ6, применяемого в авиационном двигателестроении, при торцевом фрезеровании. Расчёты проводились в САЕ-системе Deform с использованием FEM-модели.Температура резания, силы резания, реологические свойства, модель напряжённо-деформированного состояния Джонсона-Кука.

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Predictive force model for ball-end milling and experimental validation with a wavelike form machining test

Cited by 78 publications

References 25 publications

Experimental investigations from conventional to high speed milling on a 304-L stainless steel

Experimental investigations from conventional to high speed milling on a 304-L stainless steel

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

Formation of a model of rheological properties of hard-to-machine materials in the process of intensive cutting force deflection

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