Article ID Journal Published Year Pages File Type
795717 Journal of Materials Processing Technology 2007 12 Pages PDF
Abstract

This study deals with the effect of tool–surface inclination on cutting forces in ball-end milling. The following paper presents the determination of these cutting forces by using a predictive milling force model based on a thermomechanical modelling of oblique cutting. In this analytical model, the tool is supposed to be rigid and the working cutting edges are decomposed into a series of axial elementary cutting edges. At any active tooth element, the local chip formation is obtained from an oblique cutting process characterised by a local undeformed chip section and local cutting angles. This method is efficient to predict accurately the cutting force distribution on the helical ball-end mill flutes from tool geometry, pre-form surface, tool path, cutting conditions, material behaviour and friction at the tool–chip interface. The radial run-out of the tool is also taken into account in the presented work. The model is applied to ball-end milling with straight tool paths but with various tool–surface inclinations. All the ramping and contouring, up- and down-cutting configurations are tested and the results are compared with data obtained from ball-end milling experiments performed on a three-axis CNC equipped with a Kistler dynamometer.

Related Topics
Physical Sciences and Engineering Engineering Industrial and Manufacturing Engineering
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