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TECHNICAL PAPERS

3D Ball-End Milling Force Model Using Instantaneous Cutting Force Coefficients

[+] Author and Article Information
Jeong Hoon Ko

Automotive Mechatronics Center, Pohang University of Science and Technology, San 31 Hyoja-dong, Nam-gu, Pohang, Kyungbuk 790-784, South Korea

Dong-Woo Cho

Department of Mechanical Engineering, Pohang University of Science and Technology, San 31 Hyoja-dong, Nam-gu, Pohang, Kyungbuk 790-784, South Korea

J. Manuf. Sci. Eng 127(1), 1-12 (Mar 21, 2005) (12 pages) doi:10.1115/1.1826077 History: Received June 15, 2003; Revised March 13, 2004; Online March 21, 2005
Copyright © 2005 by ASME
Topics: Force , Cutting , Milling , Thickness
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References

Figures

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Definition of the cutter edge length, ds.
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Plot of ln(Kn) versus the rescaled uncut chip thickness (tcr)
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Plot of Kf versus the instantaneous uncut chip thickness (tc)
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A comparison of measured and predicted cutting forces for the cutting configuration in Fig. 17 (a) Measured cutting force Fx. (b) Predicted cutting force Fx. (c) Measured cutting force Fy. (d) Predicted cutting force Fy. (e) Measured cutting force Fz. (f ) Predicted cutting force Fz.
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Workpiece geometry for machining along an inclined path.
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A comparison of measured and predicted cutting forces for the cutting configuration in Fig. 19. (a) Measured cutting force Fx. (b) Predicted cutting force Fx. (c) Measured cutting force Fy. (d) Predicted cutting force Fy. (e) Measured cutting force Fz. (f) Predicted cutting force Fz.
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Cutting force coefficients determined along with the determined runout parameters. (Offset=0.009 mm,angle=100°.)
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Change in cutter edge length along the z-axis
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A comparison of θhl and θhlc. (α is the cutter edge location angle and R(z) is the cutter radius in the x-y plane at axial location z.)
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Plot of θc−θhlc versus the instantaneous uncut chip thickness (tc)
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A comparison of measured and predicted cutting forces for fixed cutting conditions. (a) Cutting conditions: WOC=5 mm,DOC=2.5 mm, feed rate=250 mm/min, spindle speed=1000 rpm (Test 8). (b) Cutting conditions: WOC=5 mm,DOC=2.7 mm, feed rate=70 mm/min, spindle speed=1000 rpm (Test 9). (c) Cutting conditions: WOC=5 mm,DOC=1 mm, feed rate=900 mm/min, spindle speed=9000 rpm (Test 17). (d) Cutting conditions: WOC=12 mm,DOC=4.0 mm, feed rate=100 mm/min, spindle speed=1000 rpm (Test 23). (e) Cutting conditions: WOC=5.0 mm,DOC=0.6 mm, feed rate=100 mm/min, spindle speed=2000 rpm (Test 24). (f ) Cutting conditions: WOC=5.0 mm,DOC=0.6 mm, feed rate=300 mm/min, spindle speed=6000 rpm (Test 26). (g) Cutting conditions: WOC=5.0 mm,DOC=3.0 mm, feed rate=50 mm/min, spindle speed=500 rpm (Test 27). (h) WOC=10.0 mm,DOC=3.5 mm, feed rate=70 mm/min, spindle speed=1000 rpm (Test 29).
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Workpiece geometry for machining along a wavelike path (half-radial immersion condition)
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Unit vectors on the rake surface and the geometry of a sliced disk produced by the cutter. (α is the cutter edge location angle, αr the rake angle, o̸ the angular position of the cutter edge, θ the cutter rotation angle, and R(z) indicates the local radius of the disk.) (a) Unit vectors on the rake surface. (b) Geometry of a sliced disk produced by the cutter.
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Cutter runout and the related parameters. (ρ is the radial runout offset of a cutter and αrun is its location angle.)
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Feed components in 3-axis machining. (fth is the horizontal feed component; ftz is the vertical feed component; and ψ is the feed angle.)
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Possible uncut chip thickness in three-dimensional machining
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Subtraction process for determining the cutting force coefficients
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Algorithm for determining the cutting force coefficients and runout parameters in ball-end milling. (nθ is 360°/Δθ and nf is the number of flutes.)
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Measured cutting forces used to determine the cutting force coefficients and runout parameters. (R0=5 mm,WOC=10 mm,DOC=0.3 mm, feed rate=100 mm/min, spindle speed=1000 rpm.)

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