• Title/Summary/Keyword: Ball End Mill

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A study on the surface roughness of STD 11 material according to the helix angle of ball endmill (볼 엔드밀의 헬릭스 각도에 따른 STD 11 소재의 표면 거칠기에 관한 연구)

  • Jong-Su Kim
    • Design & Manufacturing
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    • v.17 no.1
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    • pp.33-39
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    • 2023
  • The ball end mill is a type of cutting tool that is widely used to process complex mold shapes including aspheric surfaces. Unlike the flat end mill in which the cutting edge is formed on the cylindrical handle, the cutting edge is formed from the cylindrical handle to the hemispherical shape, which is advantageous for processing curved shapes. However, since the cutting speed continuously changes during machining due to the helix angle of the cutting edge or the machining inclination angle, it is difficult to obtain a precise machined surface. Therefore, in this paper, machining was performed while changing the helix angle of the ball end mill and the angle of the machining slope under the same cutting conditions for STD 11 material, which is widely used as a mold material. Through this, the effect of the two variables on the roughness of the machined surface was analyzed. As a result, if the helix angle was 0 degrees, it showed the best surface roughness of Ra. 0.16 ㎛. When the helix angle was 20 degrees, the best surface roughness of Ra. 0.18 ㎛ was occurred.

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Effect of Ball End Mill Geometry and Cutting Conditions on Machinability of Hardened Tool Steel

  • Jang, Dong-Y.;Won, S.-T.
    • KSTLE International Journal
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    • v.3 no.1
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    • pp.17-22
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    • 2002
  • Roughing of tool steel in its hardened state represents a real challenge in the die and meld industry and process improvement depends on research of tool material, coating technique, and lubrication. However, roughing of hardened steels generates extreme heat and without coolant flooding, tool material cannot withstand the high temperature without choosing the right tools with proper coating. This research conducted milling tests using coated ball end mills to study effects of cutting conditions and geometric parameters of ball end mills on the machinability of hardened tool steel. KP4 steel and STD 11 heat treated steels were used in the dry cutting as the workpiece and TiAIN coated ball end mills with side relief angle of 12$^{\circ}$ was utilized in the cutting tests. Cutting forces, tool wear, and surface roughness were measured in the cutting tests. Results from the experiments showed that 85 m/min of cutting speed and 0.32 mm/rev of feed rate were optimum conditions for better surface finish during rough cutting and 0.26mm/rev with the same cutting speed are optimum conditions in the finish cutting.

Improvement of Mold-Sculptured Surface Quality Based on Tool Shape and Posture (공구 형상 및 자세에 따른 금형 자유곡면 가공품질 향상에 관한 연구)

  • Yun, Il-Woo;Hwang, Jong-Dae;Ko, Dae-Cheol
    • Journal of the Korean Society of Manufacturing Process Engineers
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    • v.20 no.12
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    • pp.100-106
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    • 2021
  • This paper presents a study on the improvement of the machining quality of sculptured-surfaces of molds according to the shape and posture of the tool. In the existing 3-axis machining, the methods using the ball end-mill and radius end-mill were analyzed for various cutting patterns and compared with those of the 5-axis machining. It was observed that the 5-axis machining using a ball end-mill obtained the finest surface roughness, and for the 3-axis machining, the optimal results were obtained for the one-way machining using a radius end-mill.

Machining of Straight Bevel Gear Die with Crown Teeth Using Ball End Mill (볼 엔드밀을 이용한 크라운 치형을 갖는 직선 베벨기어 금형 가공)

  • Lee, Kang-Hee;Lee, Ki-Yong;Ahn, Dong-Gyu;Park, Yong-Bok
    • Transactions of the Korean Society of Machine Tool Engineers
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    • v.17 no.6
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    • pp.104-110
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    • 2008
  • A lot of straight bevel gears have been manufactured by the cold forging process in order to improve the productivity and mechanical property of the product. The die for the cold forging of the gear needs high precision and reproducibility. In the study, cold forging die has been modeled by CAD/CAM and manufactured by machining center using ball end mill coated by (Al, Ti)N for heat-treated alloy steel(STD11, HRC 60). Through the measurement of the machined die, satisfactory dimensional accuracy and surface roughness were obtained. In the future, many 3-d cold forging dies will be directly machined instead of electric discharge machining.

Cusp Height in Circular Surface Machining Using Ball End Mill (볼엔드밀을 이용한 원호곡면의 가공시 CUSP의 크기)

  • Yoon, Hee-Jung;Park, Sang-Lyang;Choi, Jong-Soon;Park, Dong-Sam
    • Proceedings of the KSME Conference
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    • 2000.04a
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    • pp.826-830
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    • 2000
  • Sculptured surface machining plays a vital role in the process of bring new Products to the market place. A great variety of products rely on this technology for the production of the dies and moulds used in manufacturing. And, the use or CNC machines and CAD/CAM system has become a vital parts or product development process. But, cusp is inevitable by-product in sculptured surface machining, and it is very difficult to calculate the cusp height correctly. In this study, an analytical cusp height model is proposed considering the radius of the ball end mill, radius of machined workpiece and the inclined angle of convex or concave circular surface. Experiments were performed to check the validity of this proposed model and experimental results showed that the proposed cusp model were very effective.

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Drilling Characteristics Using the Helical Motion of Ball End Mill Tools (볼엔드밀 공구의 헬리컬 운동을 이용한 구멍가공 특성)

  • 김근오;박규열
    • Journal of the Korean Society for Precision Engineering
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    • v.15 no.6
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    • pp.40-47
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    • 1998
  • Drilling is an indispensable process in manufacturing of the die and mould and the other mechanical parts which needs high dimensional and surface accuracy. In this paper, a new type of drilling method was proposed in order to improve both processing efficiency and accuracy. Specifically, the helical motion using ball end mill tools, instead of normal drilling method, was applied to perform an effective hole machining. In this paper, an theoretical background of the new type of drilling method was established, and the feasibility of the proposed theory was proved by experiments, where proposed drilling process in the paper gave a different machining specification than general method did.

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A Study on the Flexible Cutting Force Model in the Ball End Milling Process (볼 엔드밀 가공의 유연 절삭력 모델에 관한 연구)

  • 최종근;강윤구;이재종
    • Transactions of the Korean Society of Machine Tool Engineers
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    • v.12 no.2
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    • pp.44-52
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    • 2003
  • This research suggests a cutting force model for the ball end milling processes. This model includes the effect of tool run out and tool deflection. In the proposed model, the flutes of ball end mills are considered as series of infinitesimal elements and each cutting edge is assumed to be straight for the analysis of the oblique cutting process, in which the small cutting edge element has been analyzed as an orthogonal cutting process n the plane including the cutting velocity and the chip-flow vector. Therefor, the cutting forces can be calculated through the model using the orthogonal cutting data obtained from the orthogonal cutting test. In order to enhance the performance of the model, the flutes of ball end mill are defined to keep geometric consistency at the peak of the ball part and the junction with the end mill part. The divided infinitesimal cutting edges are regulated to be even lengths. Some experiments show the validity of the developed model in the various cutting coalitions.

Effect of Ball End Mill Cutting Environments on Machinability of Hardened Tool Steel (볼 엔드밀 가공환경 조건이 고경도 강재의 절삭 특성에 미치는 영향)

  • 이영주;원시태;허장회;박동순
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2003.10a
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    • pp.245-250
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    • 2003
  • This research conducted milling tests to study effects of cutting environment conditions of ball end mills on the characteristics of hard milling process. KP4 steels and STD11 heat treated steels were used as the workpiece and WC-Co ball end mill tools with TiAIN coated were utilized in the cutting tests. Dry cutting without coolant and semi-dry cutting using botanical oil coolant were conducted and MQL (Minimum Quantity Lubricant) device was used to spray coolant. Cutting forces, tool wear and surface roughness were measured in the cutting tests. Results showed that dry cutting of KP4 and hardened STD11 specimens produced better surface quality and wear performance than MQL spray cutting did.

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Effect of Ball End Mill Cutting Environments on Machinability of Hardened Tool Steel (볼 엔드밀 가공환경 조건이 고경도 강재의 절삭 특성에 미치는 영향)

  • 이영주;원시태
    • Transactions of Materials Processing
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    • v.13 no.1
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    • pp.45-52
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    • 2004
  • This research conducted milling tests to study effects of cutting environment conditions of ball end mills on the characteristics of hard milling process. KP4 steels and STD11 heat treated steels were used as the workpiece and WC-Co ball end mill tools with TiAlN coated were utilized in the cutting tests. Dry cutting without coolant and semi-dry cutting using botanical oil coolant were conducted and MQL(Minimum Quantity Lubricant) device was used to spray coolant. Cutting forces, tool wear and surface roughness were measured in the cutting tests. Results showed that dry cutting of KP4 and hardened STD11 specimens produced better surface quality and wear performance than MQL spray cutting did.

The Effect of Ball End Mill Cutting Environments on High Speed Machinability of Hardened Tool Steel (볼 엔드밀 가공환경조건이 고경도 강재의 고속절삭특성에 미치는 영향)

  • Lee Y. J.;Won S. T.;Hur J. H.;Park D. S.;Kim E. S.;Kim K. P.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2004.10a
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    • pp.238-244
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    • 2004
  • This research conducted milling tests to study effects of cutting environment conditions of ball end milts on the characteristics of high speed milling cutting process. KP4 steels and STD11 heat treated steels were used as the workpiece and WC-Co ball end mill tools with TiAIN coated were utilized in the cutting tests. Dry cutting without coolant and semidry cutting using botanical oil coolant by the MQL(Minimum Quantity Lubricant) device were conducted. Cutting forces, tool wear and surface roughness were measured in the cutting tests. Results showed that MQL spray cutting of KP4 and hardened STD11 specimens produced better surface quality and wear performance than dry cutting did.

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