Study of optimal cutting condition for energy efficiency improvement in ball end milling with tool-workpiece inclination

Abstract Reduced energy consumption is critical in industrial applications. In this manuscript, we report our findings on cutting condition improvement for 5-axis machine tools, specifically addressing tool angles and cutting speed in an effort to reduce energy consumption. An optimized inclined angle is determined by cutting experiments to reduce energy consumption and the basis of results are investigated. Workpieces produced under standard and improved cutting conditions are compared to verify the effects of lowered energy consumption.

[1]  Hiroyasu Iwabe,et al.  Analysis of Cutting Mechanism of Ball End Mill Using 3D-CAD (Chip Area by Inclined Surface Machining and Cutting Performance Based on Evaluation Value) , 2006 .

[2]  A. Moufki,et al.  Modelling of cutting forces in ball-end milling with tool–surface inclination: Part I: Predictive force model and experimental validation , 2007 .

[3]  Koichi Kikkawa,et al.  Theoretical Analysis on Generating Mechanism of Machined Surface in Ball-nosed End Milling for Spherical Surface. 3rd Report. Dependence of Shape of Machined Surface on Tool Orientation. , 2003 .

[4]  Eiji Shamoto,et al.  Analytical prediction of chatter stability in ball end milling with tool inclination , 2009 .

[5]  Eiji Shamoto,et al.  Analytical Prediction of Stability Lobes in Ball End Milling , 1999 .

[6]  隆 松村,et al.  曲線切れ刃形状エンドミル加工における切削力解析 : 第1報,切削力解析手法とボールエンドミル加工の解析例(機械要素,潤滑,工作,生産管理など) , 2003 .

[7]  Makoto Fujishima,et al.  A study on energy efficiency improvement for machine tools , 2011 .

[8]  Hiroyasu Iwabe,et al.  Analysis of Cutting Mechanism by Ball End Mill Using 3D-CAD , 2006 .

[9]  Lutfi Taner Tunc,et al.  Modeling and simulation of 5-axis milling processes , 2009 .

[10]  垣野 義昭,et al.  焼入鋼のエンドミル加工に関する研究(第1報) : 切削抵抗の簡易推定式とそれを用いた切削抵抗の一定化制御 , 2000 .