Abstract
There are a number of concave circular blending surfaces with minor curvature radius in the corner of curved surface part, like complex mold cavity. Pencil-cut machining has shorter path and completer material remove than other strategies of clean-up machining which make it high efficiency, high precision, and high utilization rate of equipment. In this paper, contact between cutter and concave crescent cylinder (CCC) including cutter workpiece engagement (CWE) and in-cut cutter edge (ICCE) is studied based on an analytic method, and a prediction model of the cutting force for pencil-cut machining with the ball-end mill is established. The cutter, the CCC, and the feed direction for pencil-cut machining are parametrically defined. In cutter contact normal coordinate system, the analytic expressions of tool geometry, CCC, and the cutter sweep surface of the cutter are derived, and then the CWE is obtained by the intersection of the space surfaces, which the CWE in the tool coordinate is realized by the three-dimensional rotation transformation. The cutter edge curve is discreted into a series of infinitesimal element, based on the criteria of the cutter edge element in the CWE, an analytic algorithm to calculate the ICCE is proposed, and the precision of the boundary points can be further improved by the dichotomy. Combining ICCE with instantaneous chip thickness considering cutter run-out and micro-element milling force theories of ball-end mill, the prediction model of cutting force for pencil-cut machining of CCC with ball-end mill is established. A series of pencil-cut machining experiments and simulations were arranged. The performance of pulling milling is better than that of pushing milling. The CWE and ICCE obtained by the analytical method agree well with that of experiment and solid modeling simulation. The cutting force experiments verify the correctness of the milling force predictive model.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Zhang X, Zhang J, Zhao WH (2016) A new method for cutting force prediction in peripheral milling of complex curved surface. Int J Adv Manuf Technol 86(1–4):117–128
Huang T, Zhang X, Ding H (2013) Decoupled chip thickness calculation model for cutting force prediction in five axis ball-end milling. Int J Adv Manuf Technol 69(5–8):1203–1217
Yun WS, Cho DW (2000) An improved method for the determination of 3D cutting force coefficients and runout parameters in end milling. Int J Adv Manuf Technol 16(12):851–858
Park SC, Choi BK (2001) Uncut free pocketing tool-paths generation using pair-wise offset algorithm. Comput Aided Des 33(10):739–746
Choy HS, Chan KW (2003) A corner-looping based tool path for pocket milling. Comput Aided Des 35(2):155–166
Pateloup V, Duc E, Ray P (2004) Corner optimization for pocket machining. Int J Mach Tools Manuf 44(12–13):1343–1353
Bouaziz Z, Zghal A (2008) Optimization and selection of cutters for 3D pocket machining. Int J Comput Integr Manuf 21(1):73–88
Guerrero-Villar F, Dorado-Vicente R, Romero-Carrillo P, López-García R, Mercado-Colmenero J (2015) Computation of instantaneous cutter engagement in 2.5D pocket machining. Procedia Engineering 132:464–471
Zhang L, Zheng L (2004) Prediction of cutting forces in milling of circular corner profiles. Int J Mach Tools Manuf 44:225–235
Kris AG, Law MY, Geddam A (2001) Prediction of contour accuracy in the bed milling of pockets. J Mater Process Technol 113(1–3):399–405
Dotcheva M, Millward H (2005) The application of tolerance analysis to the theoretical and experimental evaluation of a CNC corner-milling operation. J Mater Process Technol 170:284–297
Bae SH, Ko K, Bo HK, Choi BK (2003) Automatic federate adjustment for pocket machining. Comput Aided Des 35(5):195–500
Peng C, Wang L, Li Z, Yang Y (2014) Time-domain simulation and experimental verification of dynamic cutting forces and chatter stability for circular corner milling. Proc Inst Mech Eng B J Eng Manuf 229:932–939
Ren Y, Yau HT, Lee YS (2004) Clean-up tool path generation by contraction tool method for machining complex polyhedral models. Comput Ind 54:17–33
Kim DS, Jun CS, Park S (2005) Tool path generation for clean-up machining by a curve-based approach. Comput Aided Des 37:967–973
Tang M, Zhang D, Luo M, Wu B (2012) Tool path generation for clean-up machining of impeller by point-searching based method. Chin J Aeronaut 25:131–136
Zhu W, Lee YS (2004) Five-axis pencil-cut planning and virtual prototyping with 5-DOF haptic interface. Comput Aided Des 36(13):1295–1307
Ding YP, Liu XL, Shi HN, Li J, Zhang R (2014) Modeling and simulation of ball end milling force for mold cavity corner. Mater Sci Forum 800-801:337–341
Yue CX, Huang C, Liu XL, Hao SY, Liu J (2017) 3D FEM simulation of milling force in corner machining process. Chin J Mech Eng 30(2):286–293
Wei ZC, Wang MJ, Cai YJ, Wang SF (2013) Prediction of cutting force in ball-end milling of sculptured surface suing improved Z-map. Int J Adv Manuf Technol 68(5–8):1167–1177
Guo ML, Wei ZC, Wang MJ, Li SQ, Liu SX (2018) Force prediction model for five-axis flat end milling of free-form surface based on analytical CWE. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-018-2480-1
Wei ZC, Guo ML, Wang MJ, Li SQ, Liu SX (2018) Force predictive model for five axis ball end milling of sculptured surface. Int J Adv Manuf Technol 98(5–8):1367–1377
Wei ZC, Guo ML, Wang MJ, Li SQ, Liu SX (2018) Prediction of cutting force in five-axis flat end milling. Int J Adv Manuf Technol 96(1–4):137–152
Wan M, Ma CY, Zhang WH, Yang Y (2015) Study on the construction mechanism of stability lobes in milling process with multiple modes. Int J Adv Manuf Technol 79(1–4):589–603
Guo ML, Wei ZC, Wang MJ, Li SQ, Liu SX (2018) An identification model of cutting force coefficients for five-axis ball end milling. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-018-2451-6
Funding
This research is supported by the Natural Science Foundation of Liaoning No. 201602174 and the Fundamental Research Funds for the Central Universities No. DUT17GF213.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Wei, Z.C., Guo, M.L., Wang, M.J. et al. Prediction of cutting force of ball-end mill for pencil-cut machining. Int J Adv Manuf Technol 100, 577–588 (2019). https://doi.org/10.1007/s00170-018-2709-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-2709-z