Abstract
As a high precision and high efficiency cutting method, CNC milling of five axis is the first choice for manufacturing parts with complex sculptured surface. Milling force is one of the most important physical parameters in machining which affects the cutting vibration, cutting deformation, cutting heat, and surface quality directly. Aiming at the five-axis ball end milling of sculptured surface, a force predictive model with arbitrary cutter axis vector and feed direction is established. The conditions of micro-cutting edge of three-axis ball end mill involved in cutting are determined by space region limitation at the first. Then, after space rotation transformation, an analytic in-cut cutting edge (ICCE) method for five-axis ball end milling of oblique plane is proposed by judging micro-cutting edge one by one. Based on the idea of differential discretization, the machining of general complex surface can be regarded as a combination of a series of tiny oblique planes. Drawing on the idea to sculptured surface and combining micro-element milling force model and undeformed chip thickness model that is suitable for five-axis ball end milling with arbitrary feed direction, a milling force predictive model for five-axis ball end milling of sculptured surface is established. The results of simulations and experiments show that the ICCE determined by the space region limitation is consistent with the traditional Z-map method and the solid modeling method with high efficiency and precision. The measured force and the predictive force of the five-axis milling on sculptured surface are in good agreement in amplitude and trend, which proves the effectiveness of the milling force predictive model of five-axis ball end milling of sculptured surface.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Martellotti ME (1941) An analysis of the milling process. ASME J Manuf Sci Eng 63:677–700
Koenigsberger F, Sabberwal AJP (1961) An investigation into the cutting force pulsation during milling operations. Int J Mach Tool Manu 1(1–2):15–33
Tlusty J, MacNeil P (1975) Dynamics of cutting forces in end milling. CIRP Ann 24:21–25
Kline WA, DeVor RE, Lindberg JR (1982) The prediction of cutting forces in end milling with application to cornering cuts. Int J Mach Tool Manu 22:7–22
Yang MY, Park H (1991) The prediction of cutting force in ball-end milling. Int J Mach Tool Manu 31(1):45–54
Yucesan G, Altintas Y (1996) Prediction of ball end milling forces. J Eng Ind 118(1):95–103
Wang JJJ, Huang CY (2004) A force-model-based approach to estimating cutter axis offset in ball end milling. Int J Adv Manuf Technol 24(11–12):910–918
Tsai CL, Liao YS (2010) Cutting force prediction in ball-end milling with inclined feed by means of geometrical analysis. Int J Adv Manuf Technol 46:529–541
Azeem A, Feng HY (2013) Cutting force prediction for ball-end mills with non-horizontal and rotational cutting motions. Int J Adv Manuf Technol 67(5–8):1833–1845
Imania BM, Sadeghib MH, Elbestawi MA (1998) An improved process simulation system for ball-end milling of sculptured surfaces. Int J Mach Tool Manu 38(9):1089–1107
Guzel BU, Lazoglu I (2004) An enhanced force model for sculptured surface machining. Mach Sci Technol 8(3):431–448
Sun YW, Ren F, Guo DM, Jia ZY (2009) Estimation and experimental validation of cutting forces in ball-end milling of sculptured surfaces. Int J Mach Tool Manu 49(15):1238–1244
Wei ZC, Wang MJ, Cao YJ, Wang SF (2013) Prediction of cutting force in ball-end milling of sculptured surface using improved Z-map. Int J Adv Manuf Technol 51(5):428–432
Jia ZY, Ge J, Ma JW, Gao YY, Liu Z (2016) A new cutting force prediction method in ball-end milling based on material properties for difficult-to-machine materials. Int J Adv Manuf Technol 86:2807–2822
Fontaine M, Devillez A, Moufki A, Dudzinski D (2006) Predictive force model for ball-end milling and experimental validation with a wavelike form machining test. Int J Mach Tool Manu 46(3):367–380
Ozturk E, Budak E (2005) Modeling of 5-axis milling forces. Proceedings of the 8th CIRP International Workshop Model Machining Operations, May 10–11, Chemnitz, Germany, 319–332
Ozturk E, Budak E (2007) Modeling of 5-axis milling processes. Mach Sci Technol 11(3):287–311
Boz Y, Erdim H, Lazoglu I (2011) Modeling cutting forces for 5-axis machining of sculptured surfaces. Adv Mater Res 223:701–712
Yang Y, Zhang WH, Wan M, Ma YC (2013) A solid trimming method to extra cutter-workpiece engagement maps for multi-axis milling. Int J Adv Manuf Technol 68(9–12):2801–2813
Zhu RX, Kapoor SG, DeVor RE (2001) Mechanistic modeling of the ball end milling process for multi-axis machining of free-form surfaces. J Manuf Sci Eng 123(3):369–379
Fussell BK, Jerard RB, Hemmett JG (2003) Modeling of cutting geometry and forces for 5-axis sculptured surface machining. Comput Aided Des 35(4):333–346
Guo DM, Ren F, Sun YW (2010) An approach to modeling cutting forces in five-Axis ball-End milling of curved geometries Based on tool motion analysis. J Manuf Sci Eng 132(4):575–590
Wang SB, Geng L, Zhang YF, Liu K, Ng TE (2015) Cutting force prediction for five-axis ball-end milling considering cutter vibrations and run-out. Int J Mech Sci 96–97:206–215
Geng L, Liu PL, Liu K (2015) Optimization of cutter posture based on cutting force prediction for five-axis machining with ball-end cutters. Int J Adv Manuf Technol 78(5–8):1289–1303
Sun Y, Guo Q (2011) Numerical simulation and prediction of cutting forces in five-axis milling processes with cutter run-out. Int J Mach Tool Manu 51(10):806–815
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):1203–1121
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. Force predictive model for five-axis ball end milling of sculptured surface. Int J Adv Manuf Technol 98, 1367–1377 (2018). https://doi.org/10.1007/s00170-018-2125-4
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-2125-4