A geometrical simulation system of ball end finish milling process and its application for the prediction of surface micro features

Journal of Manufacturing Science and Engineering

Volumn 128, Issue 1, 2006, Pages 74-85

  Liu, Xianbing ^a   Soshi, Masakazu ^a   Sahasrabudhe, Abhijit ^a   Yamazaki, Kazuo ^a   Mori, Masahiko ^b  

^a Davis   (United States)

^b Mori Seiki Co   (Japan)

Author keywords

[No Author keywords available]

Indexed keywords

COMPUTER SIMULATION; DIES; GEOMETRY; PRECISION ENGINEERING; REAL TIME SYSTEMS; SURFACE STRUCTURE;

FINISH MILLING; SURFACE MICRO FEATURES; TOOL INCLINATION;

BALL MILLING;

EID: 33645309614     PISSN: 10871357     EISSN: None     Source Type: Journal    
DOI: 10.1115/1.2039098     Document Type: Article

References (35)

1. Altan, T., Lilly, B. W., Kruth, J. P., Konig, W., Tonshoff, H. K., van Luttervelt, C. A., and Khairy, A. B., 1993, "Advanced Techniques for Die and Mold Manufacturing," CIRP Ann. 42(2), pp. 707-716.
2. Shaw, M. C., Cook, N. H., and Smith, P. A., 1952, "The Mechanics of Three-Dimensional Cutting Operations," Trans. ASME, 74, pp. 1055-1064.
3. Kline, W. A., DeVor, R. E., and Lindberg, J. R., 1982, "The Prediction of Cutting Forces in End Milling With Application to Cornering Cuts," Int. J. Mach. Tool Des. Res., 22, pp. 7-22.
4. Kline, W. A., and DeVor, R. E., 1983, "The Effect of Run-Out on Cutting Geometry and Forces in End Milling," Int. J. Mach. Tool Des. Res., 23, pp. 123-140.
5. Kline, W. A., DeVor, R. E., and Shareef, I. A., 1982, "The Prediction of Surface Accuracy in End Milling," ASME J. Eng. Ind., 104, pp. 272-278.
6. Ehmann, K. F., Kapoor, S. G., DeVor, R. E., and Lazoglu, I., 1999, "Machining Process Modeling: A Review," ASME J. Manuf. Sci. Eng., 119, pp. 655-663.
7. Lazoglu, I., and Liang, S. Y., 2000, "Modeling of Ball-End Milling Forces With Cutter Axis Inclination," ASME J. Manuf. Sci. Eng., 122, pp. 3-11.
8. Zhu, R., DeVor, R. E., and Kapoor, S. G., 2001, "Mechanistic Modeling of the Ball-End Milling Process for Multi-Axis Machining of Free-Form Surfaces," ASME J. Manuf. Sci. Eng., 123, pp. 369-379.
9. Stori, J. A., and Wright, P. K., 2001, "Parameter Space Decomposition for Selection of the Axial and Radial Depth of Cut in End Milling," ASME J. Manuf. Sci. Eng., 123, pp. 654-664.
10. Wang, W. P., and Wang, K. K., 1986, "Geometric Modeling for Swept Volume of Moving Solids," IEEE Comput. Graphics Appl., 6, pp. 8-17.
11. Wang, W. P., 1988, "Application of Solid Modeling to Automate Machining Parameters for Complex Parts," J. Manuf. Syst., 17(1), pp. 57-63.
12. Hook, T. V. 1986, "Real-Time Shaded NC Milling Display," Proc. ACM, 20(4), pp. 15-20.
13. Huang, Y. C., and Oliver, J. H., 1995, "Integrated Simulation, Error Assessment and Tool Path Correction for Five-Axis NC Milling," J. Manuf. Syst., 14(5), pp. 331-344.
14. Tsai, M. D., Takata, S., Inui, M., Kimura, F., and Sata, T., 1990, "Prediction of Chatter Vibration by Means of a Model Based Cutting Simulation System," CIRP Ann., 39(1), pp. 447-450.
15. Fussell, B. K., Jerard, R. B., and Hemmett, J. G., 2001, "Robust Feedrate Selection for 3-Axis NC Machining Using Discrete Models," ASME J. Manuf. Sci. Eng., 123, pp. 214-224.
16. Anderson, R. O., 1978, "Detecting and Eliminating Collision in NC Machining," Comput.-Aided Des., 10(2), pp. 231-237.
17. Kim, G. M., Cho, P. J., and Chu, C. N., 2000, "Cutting Force Prediction of Sculptured Surface Ball End Milling Using Z-Map," Int. J. Mach. Tools Manuf., 40, pp. 277-291.
18. Yazar, Z., Koch, K. F., Merrick, T., and Allan, T., 1994, "Feedrate Optimization Based on Cutting Force Calculations in 3-Axis Milling of Dies and Molds With Sculptured Surfaces," Int. J. Mach. Tools Manuf., 34, pp. 365-377.
19. Choi, B. K., Kim, D. H., and Jerard, R. B., 1997, "C-Space Approach to Tool Path Generation for Die and Mould Machining," Comput.-Aided Des., 29(9), pp. 657-669.
20. Lee, S., and Ko, S., 2002, "Development of Simulation System for Machining Process Using Enhanced Z Map Model," J. Mater. Process. Technol., 130-131, pp. 608-617.
21. Lee, H. U., and Cho, D., 2003, "Accurate Milling Process Simulation Using ME Z-Map Model," Proceedings of IMECE'03, ASME, New York, pp. 1-7.
22. Kim, B. H., and Chu, C. N., 1994, "Effect of Cutter Mark on Surface Roughness and Scallop Height in Sculptured Surface Machining," Comput.-Aided Des., 26(3), pp. 179-188.
23. Kim, B. H., and Chu, C. N., 1999, "Texture Prediction of Milled Surfaces Using Texture Superposition Method," Comput.-Aided Des., 31, pp. 485-494.
24. Campomanes, M. L., and Altintas, Y., 2003, "An Improved Time Domain Simulation for Dynamic Milling at Small Radial Immersions," ASME J. Manuf. Sci. Eng., 125, pp. 416-422.
25. Yang, M., and Park, H., 1991, "The Prediction of Cutting Force in Ball End Milling,", 31, pp. 45-54.
26. Yucesan, G., and Altintas, Y., 1996, "Prediction of Ball End Milling Forces," ASME J. Eng. Ind., 118, pp. 95-103.
27. Koreta, N., Zhao, X., and Kubo, K., 2002, "Optimum Tilting Direction and Angle of Tool for Surface Roughness in Ball-End Milling," 6th International Conference on Progress of Machining Technology, pp. 476-481.
28. Antoniadis, A., 2001, "Simulation of Milled Surface Topomorphy," ACM Trans. Model. Comput. Simul., 21(4) pp. 271-274.
29. Sarma, R., 2000, "Flat-Ended Tool Swept Sections for Five-Axis NC Machining of Sculptured Surfaces," ASME J. Manuf. Sci. Eng., 122, pp. 158-165.
30. Armarego, E. J. A., and Deshpande, N. P., 1991, "Computerized End-Milling Force Prediction With Cutting Models Allowing for Eccentricity and Cutter Deflections," CIRP Ann., 40(1), pp. 25-29.
31. Yun, W., Cho, D., and Ehmann, K. F., 1999, "Determination of Constant 3D Cutting Force Coefficients and of Run-Out Parameters in End Milling," Trans. NAMRC/SME, XXVII, pp. 87-92.
32. Kline, W. A., DeVor, R. E., and Shareef, I. A., 1982, "The Prediction of Surface Accuracy in End Milling," ASME J. Eng. Ind., 104, pp. 272-278.
33. Dong, W. P., Mainsah, E. and Stout, K. J., 1995, "Reference Planes for the Assessment of Surface Roughness in Three Dimensions," Int. J. Mach. Tools Manuf., 35(2), pp. 263-271.
34. Choi, B., and Jerard, R., 1998, Sculptured Surface Machining-Theory and Application, Kluwer, Dordrecht.
35. Ko, T. J., Kim, H. S., and Lee, S. S., 2001, "Selection of the Machining Inclination Angle in High-Speed Ball End Milling," Int. J. Adv. Manuf. Tech-nol., 17, pp. 163-170.