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research-article

CUTTING FORCE PREDICTION OF BALL END MILLING BASED ON FULLY VOXEL REPRESENTATION OF CUTTING EDGE AND INSTANTANEOUS WORKPIECE SHAPE

[+] Author and Article Information
Isamu Nishida

Kobe University, 1-1 Rokko-dai, Nada-ku, Kobe, Hyogo, 657-8501 Japan
nishida@mech.kobe-u.ac.jp

Ryuma Okumura

Kobe University, 1-1 Rokko-dai, Nada-ku, Kobe, Hyogo, 657-8501 Japan
165t322t@stu.kobe-u.ac.jp

RYUTA Sato

Kobe University, 1-1 Rokko-dai, Nada-ku, Kobe, Hyogo, 657-8501 Japan
sato@mech.kobe-u.ac.jp

Keiichi Shirase

Kobe University, 1-1 Rokko-dai, Nada-ku, Kobe, Hyogo, 657-8501 Japan
shirase@mech.kobe-u.ac.jp

1Corresponding author.

ASME doi:10.1115/1.4038499 History: Received April 01, 2017; Revised November 09, 2017

Abstract

A new cutting force simulator has been developed to predict cutting force in ball end milling. In this simulator, uncut chip thickness is discretely calculated based on fully voxel models representing both cutting edge and instantaneous workpiece shape. In our previous simulator, a workpiece voxel model was used to calculate uncut chip thickness under a complex change of workpiece shape. Using a workpiece voxel model, uncut chip thickness is detected by extracting the voxels removed per cutting tooth for the amount of material fed into the cutting edge. However, it is difficult to define the complicated shape of cutting edge, because the shape of cutting edge must be defined by mathematical expression. It is also difficult to model the voxels removed by the cutting edge when tool posture is non-uniformly changed. Therefore a new method to detect uncut chip thickness is proposed, one in which both cutting edge and instantaneous workpiece shape are fully represented by a voxel model. Our new method precisely detects uncut chip thickness at minute tool rotational angles, making it possible to detect the uncut chip thickness between the complex surface shape of the workpiece and the particular shape of the cutting edge. To validate the effectiveness of our new method, experimental 5-axis milling tests using ball end mill were conducted. Estimated milling forces for several tool postures were found to be in good agreement with the measured milling forces. Results from the experimental 5-axis milling validate the effectiveness of our new method.

Copyright (c) 2017 by ASME
Topics: Cutting , Milling , Shapes
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