Research Papers

An Approach to Modeling Cutting Forces in Five-Axis Ball-End Milling of Curved Geometries Based on Tool Motion Analysis

[+] Author and Article Information
Guo Dongming, Ren Fei, Sun Yuwen

Key Laboratory for Precision and Non-Traditional Machining Technology of the Ministry of Education, Dalian University of Technology, Dalian 116024, China

J. Manuf. Sci. Eng 132(4), 041004 (Jul 22, 2010) (8 pages) doi:10.1115/1.4001420 History: Received July 20, 2009; Revised February 12, 2010; Published July 22, 2010; Online July 22, 2010

The prediction of five-axis ball-end milling forces is quite a challenge due to difficulties of determining the underformed chip thickness and engaged cutting edge. To solve these concerns, this paper presents a new mechanistic model of cutting forces based on tool motion analysis. In the model, for undeformed chip thickness determination, an analytical model is first established to describe the sweep surface of cutting edge during the five-axis ball-end milling process of curved geometries. The undeformed chip thickness is then calculated according to the real kinematic trajectory of cutting edges under continuous change of the cutter axis orientation. A Z-map method is used to verify the engaged cutting edge and cutting coefficients are subsequently calibrated. The mechanistic method is applied to predict the cutting force. Validation tests are conducted under different cutter postures and cutting conditions. The comparison between predicted and measured values demonstrates the applicability of the proposed prediction model of cutting forces.

Copyright © 2010 by American Society of Mechanical Engineers
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Figure 1

Framework of five-axis ball-end milling process

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Figure 2

Reference coordinates systems description for five-axis machining

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Figure 3

Schematic diagram of undeformed chip thickness calculation in five-axis ball-end milling

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Figure 4

Example sweep surface of cutting edge for ball-end milling of turbine blade

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Figure 5

Algorithm for estimating the candidate points for chip thickness calculation

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Figure 6

Calibrated cutting coefficients

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Figure 7

Five-axis milling experiment

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Figure 8

Comparison for tests

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Figure 9

Cutting test II: Cutting strategy and test part geometry, photography of machined part, and measured and simulated forces



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