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Research Papers

Cutting Force Simulation in Minute Time Resolution for Ball End Milling Under Various Tool Posture

[+] Author and Article Information
Isamu Nishida

Department of Mechanical Engineering,
Graduate School of Engineering,
Kobe University,
1-1 Rokko-dai, Nada-ku,
Kobe 657-8501, Hyogo, Japan
e-mail: nishida@mech.kobe-u.ac.jp

Ryuma Okumura

Department of Mechanical Engineering,
Graduate School of Engineering,
Kobe University,
Rokko-dai, Nada-ku,
Kobe 657-8501, Hyogo, Japan
e-mail: 165t322t@stu.kobe-u.ac.jp

Ryuta Sato

Department of Mechanical Engineering,
Graduate School of Engineering,
Kobe University,
1-1 Rokko-dai, Nada-ku,
Kobe 657-8501, Hyogo, Japan
e-mail: sato@mech.kobe-u.ac.jp

Keiichi Shirase

Department of Mechanical Engineering,
Graduate School of Engineering,
Kobe University,
1-1 Rokko-dai, Nada-ku,
Kobe 657-8501, Hyogo, Japan
e-mail: shirase@mech.kobe-u.ac.jp

1Corresponding author.

Manuscript received April 1, 2017; final manuscript received November 9, 2017; published online December 18, 2017. Assoc. Editor: Christopher Tyler.

J. Manuf. Sci. Eng 140(2), 021009 (Dec 18, 2017) (6 pages) Paper No: MANU-17-1213; doi: 10.1115/1.4038499 History: Received April 01, 2017; Revised November 09, 2017

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 the 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 nonuniformly 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 rotation 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 five-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 five-axis milling validate the effectiveness of our new method.

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References

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Figures

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Fig. 4

Extraction of removal voxels in our new simulator for each minute tool rotation angle analysis: (a) extraction of removal voxels by each minute tool rotation angle and (b) minute disk element of the cutting edge

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Fig. 3

Extraction of removal voxels in our previous simulator for each feed per tooth analysis

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Fig. 2

Geometric relationship of ball end mill

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Fig. 1

Tool model and uncut chip thickness

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Fig. 9

Workpiece with open slot in the cutting experiment (pattern 1)

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Fig. 10

Changing posture of the cutting tool in the cutting experiment

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Fig. 5

Comparison of conventional method and proposed method for tool cutting edge trajectory and cusp shape

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Fig. 6

Geometric relationship between the removal voxels and the axis components hx, hy, and hz

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Fig. 7

Precision of uncut chip thickness depending on voxel size

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Fig. 8

Simulation result of cutting force depending on voxel size

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Fig. 11

A simulation of the voxel model

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Fig. 12

Measured and estimated cutting force (pattern 1)

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Fig. 13

Measured and estimated cutting force (pattern 2): (a) lead angle 15 deg and (b) lead angle 30 deg

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