Journal ArticleDOI
The prediction of dimensional error for sculptured surface productions using the ball-end milling process. Part 2: Surface generation model and experimental verification
Ee Meng Lim,Chia-Hsiang Menq +1 more
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TLDR
In this paper, a tool deflection model is developed to calculate the corresponding horizontal tool-deflection at the surface generation points on the cutter, and the sensitivity of the machining errors to tool deflections, both in magnitude and direction, has been analyzed via the deflection sensitivity of surface geometry.Abstract:
This paper presents a surface generation model for sculptured surface productions using the ball-end milling process. In this model, machining errors caused by tool deflections are studied. As shown in Part 1 of this paper, instantaneous horizontal cutting forces can be evaluated from the cutting geometries using mechanistic force models. In this paper, a tool deflection model is developed to calculate the corresponding horizontal tool deflection at the surface generation points on the cutter. The sensitivity of the machining errors to tool deflections, both in magnitude and direction, has been analyzed via the deflection sensitivity of the surface geometry. Machining errors are then determined from the tool deflection and the deflection sensitivity of the designed surface. The ability of this model in predicting dimensional errors for sculptured surfaces produced by the ball-end milling process has been verified by a machining experiment. In addition to providing a means to predict dimensional accuracy prior to actual cutting, this surface generation model can also be used as a tool for quality control and machining planning.read more
Citations
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Journal ArticleDOI
Milling error prediction and compensation in machining of low-rigidity parts
TL;DR: In this paper, a new integrated methodology for modelling and prediction of surface errors caused by deflection during machining of low-rigidity components is proposed. But this approach is based on identifying and modelling key processing characteristics that influence part deflection, predicting the workpiece deflection through an adaptive flexible theoretical force-FEA deflection model and providing an input for downstream decision making on error compensation.
Journal ArticleDOI
Estimation of cutter deflection and form error in ball-end milling processes
TL;DR: In this paper, a method to analyze the 3D form error of a ball-end milled surface due to the elastic compliance of the cutting tool is presented. But the method is limited to the case where the holder is assumed to be a cantilever beam.
Journal ArticleDOI
Tool force and deflection compensation for small milling tools
TL;DR: In this paper, an open-loop technique was used to estimate the cutting and thrust forces, applying these forces to the tool, calculating the shape error due to tool deflection and creating a new tool path to eliminate this error.
Journal ArticleDOI
A study of the effects of cutter path strategies and orientations in milling
TL;DR: In this paper, the authors identify and review three main areas of literature studies namely analytical analysis on plane milling, entrance and exit effects of the cutter motion and inclined milling effects.
Journal ArticleDOI
Surface topography analysis in high speed finish milling inclined hardened steel
TL;DR: In this article, the surface texture of a milled surface is assessed with regards to different cutter path orientations on its surface and the conclusion is that milling in a single direction vertical upward orientation gave the best workpiece surface texture.
References
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Journal ArticleDOI
The prediction of cutting forces in end milling with application to cornering cuts
TL;DR: In this article, the authors present a mechanistic model for the force system in end milling, which is based on chip load, cut geometry, and the relationship between cutting forces and chip load.
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An Improved Method for Cutting Force and Surface Error Prediction in Flexible End Milling Systems
Journal ArticleDOI
A Cutting Simulation System for Machinability Evaluation Using a Workpiece Model
TL;DR: In this article, a cutting simulation system is described to evaluate machinability of products at various stages of the manufacturing process, which is performed by using extended Z buffer models representing a workpiece and a tool swept volume.