Cutting force prediction for ball nose milling of inclined surface

Ball nose milling of complex surfaces is common in the die/mould and aerospace industries. A significant influential factor in complex surface machining by ball nose milling for part accuracy and tool life is the cutting force. There has been little research on cutting force model for ball nose milling on inclined planes. Using such a model ,and by considering the inclination of the tangential plane at the point of contact of the ball nose model, it is possible to predict the cutting force at the particular cutting contact point of the ball nose cutter on a sculptured surface. Hence, this paper presents a cutting force model for ball nose milling on inclined planes for given cutting conditions assuming a fresh or sharp cutter. The development of the cutting force model involves the determination of two associated coefficients: cutting and edge coefficients for a given tool and workpiece combination. A method is proposed for the determination of the coefficients using the inclined plane milling data. The geometry for chip thickness is considered based on inclined surface machining with overlapping of previous pass. The average and maximum cutting forces are considered. These two forces have been observed to be more dominating force-based parameters or features with high correlation with tool wear. The developed cutting force model is verified for various cutting conditions.

[1]  Shih-Chieh Lin,et al.  Tool wear monitoring in face milling using force signals , 1996 .

[2]  Toshiki Hirogaki,et al.  Basic study of ball end milling on hardened steel , 2001 .

[3]  M. A. Elbestawi,et al.  Process monitoring in milling by pattern recognition , 1989 .

[4]  David K. Aspinwall,et al.  High Speed Ball Nose End Milling of Inconel 718 , 2000 .

[5]  Richard E. DeVor,et al.  Mechanistic Modeling of the Ball End Milling Process for Multi-Axis Machining of Free-Form Surfaces , 2001 .

[6]  Hsi-Yung Feng,et al.  The prediction of cutting forces in the ball-end milling process—I. Model formulation and model building procedure , 1994 .

[7]  Hsi-Yung Feng,et al.  A Mechanistic Cutting Force Model for 3D Ball-end Milling , 2001 .

[8]  Ibrahim N. Tansel,et al.  Modeling micro-end-milling operations. Part I: analytical cutting force model , 2000 .

[9]  Santanu Das,et al.  Force Parameters for On-line Tool Wear Estimation: A Neural Network Approach , 1996, Neural Networks.

[10]  Yusuf Altintas,et al.  In-Process Detection of Tool Failure in Milling Using Cutting Force Models , 1989 .

[11]  Jeong-Du Kim,et al.  Development of a tool failure detection system using multi-sensors , 1996 .

[12]  Yusuf Altintas,et al.  Prediction of ball-end milling forces from orthogonal cutting data , 1996 .

[13]  A. Lamikiz,et al.  Cutting force estimation in sculptured surface milling , 2004 .

[14]  Yusuf Altintas,et al.  Prediction of Ball End Milling Forces , 1996 .

[15]  Ismail Lazoglu,et al.  Machining of free-form surfaces. Part II: Calibration and forces , 2006 .

[16]  E. Lepa,et al.  Principles of machining by cutting, abrasion and erosion , 1976 .

[17]  C. M. Zheng,et al.  Estimation of in-process cutting constants in ball-end milling , 2003 .

[18]  Min-Yang Yang,et al.  The prediction of cutting force in ball-end milling , 1991 .

[19]  Herbert Schulz,et al.  High-speed milling of dies and moulds - cutting conditions and technology , 1995 .