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TECHNICAL PAPERS

Modeling of Ball-End Milling Forces With Cutter Axis Inclination

[+] Author and Article Information
Ismail Lazoglu

Steven Y. Liang

The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332

J. Manuf. Sci. Eng 122(1), 3-11 (Feb 01, 1999) (9 pages) doi:10.1115/1.538885 History: Received October 01, 1997; Revised February 01, 1999
Copyright © 2000 by ASME
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References

Yang,  M. Y., and Park,  H., 1991, “The Prediction of Cutting Force in Ball End Milling,” Int. J. Mach. Tools Manufact., 31, pp. 45–54.
Yucesan, G., and Altintas, Y., 1993, “Mechanics of Ball End Milling Process,” ASME Winter Annual Meeting, PED, Vol. 64, pp. 543–551.
Sim,  C., and Yang,  M., 1993, “The Prediction of Cutting Force in Ball End Milling with a Flexible Cutter,” Int. J. Mach. Tools Manufact., 33, pp. 267–284.
Feng,  H-S., and Menq,  C-H., 1994, “The Prediction of Cutting Forces in the Ball End Milling Process—I. Model Formulation and Model Building Procedure, II. Cut Geometry Analysis and Model Verification,” Int. J. Mach. Tools Manufact., 34, pp. 697–719.
Lazoglu, I., and Liang, S. Y., 1995, “Analysis of Force System in Ball-End Milling,” ASME Winter Annual Meeting, Manufacturing Science and Engineering, MED-Vol. 2-1, MH-Vol. 3-1, pp. 179–187.
Altintaş, Y., and Lee, P., 1995, “Combined Mechanics and Dynamics of Ball End Milling,” ASME Winter Annual Meeting, MED-Vol. 2-1/MH-Vol. 3-1, pp. 657–677.
Lee,  P., and Altintaş,  Y., 1996, “Prediction of Ball-End Milling Forces From Orthogonal Cutting Data,” Int. J. Mach. Tools Manufact., 36, pp. 1059–1072.
Lazoglu,  I., and Liang,  S. Y., 1997, “Analytical Modelling of Ball-End Milling Forces,” Int. J. Mach. Sci. Technol., 1, No. 2, pp. 219–234.
Hwang,  J. S., 1992, “Interference-free Tool-Path Generation in the NC Machining of Parametric Compound Surfaces,” Comput. Aided Des., 24, No. 12, pp. 667–676.
Cho,  J. H., and Kim,  K., 1996, “Tool Interference Detection and Correction in CNC Tool Path Planning for Sculpture Surfaces,” Trans. NAMRI/SME, 24, pp. 75–80.
Wang,  J. J., Liang,  S. Y., and Book,  W. J., 1994, “Convolution Analysis of Milling Forces Pulsation,” ASME J. Eng. Ind., 116, pp. 17–25.

Figures

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Geometry of ball-end mill (a) top view (b) front view (c) side view
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Illustration of local helix angle in ball-end mill
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Variation of local helix angle, λ1, with ψ and β angles for the cutter used in the experiments
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Variation of tc/tx in the θ−ψ domain for the values of θ1=40 deg,θ2=180 deg,ψ1=60 deg,ψ2=90 deg
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Illustration of differential chip volume and average chip thickness
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Illustration of an inclined ball-end mill
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Illustration of differential chip area
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Illustration of differential cutting force components
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Relationship between the angles in ball-end milling
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Variation of the cutting force coefficients with the average chip thickness; circles are for the values of these coefficients determined from the calibration tests, lines are for their regressional relationships to the average chip thickness (mm) as given in Eq. (23)
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Frequency spectrum of measured forces and their t̄c based analytical predictions for Test A
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Measured forces and their t̄c based estimations for Test A in the angular domain
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Frequency spectrum of measured forces and their t̄c based analytical predictions for Test B
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Measured forces and their t̄c based estimations for Test B in the angular domain
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Frequency spectrum of measured forces and their t̄c based analytical predictions for Test C
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Measured forces and their t̄c based estimations for Test C in the angular domain

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