Prediction of Ball End Milling Forces

Mechanics of milling with ball ended helical cutters are modeled. The model is based on the analytic representation of ball shaped helical flute geometry, and its rake and clearance surfaces. It is assumed that friction and pressure loads on the rake face are proportional to the uncut chip thickness area. The load on the flank contact face is concentrated on the in cut portion of the cutting edge. The pressure and friction coefficients are identified from a set of slot ball end milling tests at different feeds and axial depth of cuts, and are used to predict the cutting forces for various cutting conditions. The experimentally verified model accurately predicts the cutting forces in three Cartesian directions.

[1]  Abdel E. Bayoumi,et al.  Tool wear modeling through an analytic mechanistic model of milling processes , 1992 .

[2]  Yusuf Altintas,et al.  End Milling Force Algorithms for CAD Systems , 1991 .

[3]  L. A. Kendall,et al.  An analytic mechanistic cutting force model for milling operations: a theory and methodology , 1994 .

[4]  Abdel E. Bayoumi,et al.  Determination of process parameters through a mechanistic force model of milling operations , 1993 .

[5]  G. V. Stabler.  The Fundamental Geometry of Cutting Tools , 1951 .

[6]  S. Smith,et al.  An Overview of Modeling and Simulation of the Milling Process , 1991 .

[7]  I. Yellowley,et al.  Observations on the mean values of forces, torque and specific power in the peripheral milling process , 1985 .

[8]  Yusuf Altintas,et al.  Mechanism of Cutting Force and Surface Generation in Dynamic Milling , 1991 .

[9]  E.J.A. Armarego,et al.  Computerized End-Milling Force Predictions with Cutting Models Allowing for Eccentricity and Cutter Deflections , 1991 .

[10]  F. Koenigsberger,et al.  An investigation into the cutting force pulsations during milling operations , 1961 .

[11]  Richard E. DeVor,et al.  The effect of runout on cutting geometry and forces in end milling , 1983 .

[12]  Yusuf Altintas,et al.  Prediction of Milling Force Coefficients From Orthogonal Cutting Data , 1996 .

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

[14]  Yusuf Altintas,et al.  Improved modelling of cutting force coefficients in peripheral milling , 1994 .

[15]  L. A. Kendall,et al.  An analytic mechanistic cutting force model for milling operations: a case study of helical milling operation , 1994 .

[16]  F. Hashimoto,et al.  The mechanics of Three-dimensional Cutting Operations , 1960 .