The Effect of the Feed Direction on the Micro- and Macro Accuracy of 3D Ball-end Milling of Chromium-Molybdenum Alloy Steel

Abstract

The machining of free form surfaces is one of the most challenging problems in the field of metal cutting technology. The produced part and machining process should satisfy the working, accuracy, and financial requirements. The accuracy can describe dimensional, geometrical, and surface roughness parameters. In the current article, three of them are investigated in the case of the ball-end milling of a convex and concave cylindrical surface form 42CrMo4 steel alloy. The effect of the tool path direction is investigated and the other cutting parameters are constant. The surface roughness and the geometric error are measured by contact methods. Based on the results, the surface roughness, dimensional error, and the geometrical error mean different aspects of the accuracy, but they are not independent from each other. The investigated input parameters have a similar effect on them. The regression analyses result a very good liner regression for geometric errors and shows the importance of surface roughness.

Multi-Objective Optimization via GA Based on Micro Laser Line Scanning Data for Micro-Scale Surface Modeling

“…Based on these statements, the micro-scale flat and free-form surface modeling via multi-objective optimization enhanced the fitting accuracy of the optical microscope systems. Typically, the microscope systems perform the micro-scale flat and free-form surface modeling with a relative error over 4.6% [45,46], where the flat and free-form surface modeling is optimized through the least-squares method [47,48]. Additionally, the contour data accuracy is related to the fitting accuracy of the surface model.…”

CAD modelling of the chip shape in case of ball-end milling

“…The chip removal is simulated in a 3D virtual environment. The aim of the research is to investigate the accuracy of surfaces machined with a ball-end mill, primarily to investigate the relationship between milling strategy and shape accuracy [8,9]. The purpose of this is to be able to choose the appropriate milling strategy, taking into account the micro-and macroaccuracy of the surface, and to determine its technological and geometric parameters when using CAM systems.…”