• Title/Summary/Keyword: Ball End Mill

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An Experimental Study on the Dimensional Error in Ball End Milling (볼 엔드밀 가공에서 치수오차에 관한 실험적 연구)

  • 심기중;유종선;정진용;서남섭
    • Journal of the Korean Society for Precision Engineering
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    • v.21 no.7
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    • pp.62-69
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    • 2004
  • This paper presents an experimental study on the dimensional error in ball-end milling. In the 3D free-formed surface machining using ball-end milling, while machining conditions are varied due to the Z component of the feed and existing hemisphere part of the ball-end mill, the mechanics of ball-end milling are complicated. In the finishing, most of cutting is performed the ball part of the cutter and the machined surface are required the high quality. But the dimensional errors in the ball-end milling are inevitably caused by tool deflection, tool wear, thermal effect and machine tool errors and so on. Among these factors, the most significant one of dimensional error is usually known as tool deflection. Tool deflection is related to the instantaneous horizontal cutting force and varied the finishing cutting path. It lead to decrease cutting area, thus resulting cutting forces but the dimensional precision surface could not be obtained. So the machining experiments are conducted fur dimensional error investigation and these results may be used for decrease dimensional errors in practice.

Analysis of Machined Surfaces by Ball-end Milling using the Ridge Method (능선 궤적법을 이용한 볼엔드밀 가공면 해석)

  • 정태성;남성호;박진호;양민양
    • Journal of the Korean Society for Precision Engineering
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    • v.21 no.1
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    • pp.51-60
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    • 2004
  • Ball-end milling is one of the most common manufacturing processes for the parts with sculptured surface. However, the conventional roughness model is not suitable for the evaluation of surface texture and roughness under highly efficient machining conditions. Therefore, a different approach is needed for the accurate evaluation of machined surface. In this study, a new method, named ‘Ridge method’, is proposed for the effective prediction of the geometrical roughness and the surface topology in ball-end milling. Theoretical analysis of a machined surface texture was performed considering the actual trochoidal trajectories of cutting edge. The characteristic lines of cut remainder are defined as three-types of ‘Ridges’ and their mathematical equations are derived from the surface generation mechanism of ball-end milling process. The predicted results are compared with the results of conventional method. The agreement between the results predicted by the proposed method and the values calculated by the simulation method shows that the analytic equations presented in this paper are useful for evaluating a geometrical surface roughness of ball -end milling process.

Dynamic Model in Ball End Milling of Inclined Surface (볼 엔드밀 경사면 가공의 동적 모델)

  • Kim Seung-Yoon;Kim Byung-Hee;Chu Chong-Nam;Lee Young-Soo
    • Journal of the Korean Society for Precision Engineering
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    • v.23 no.3 s.180
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    • pp.39-46
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    • 2006
  • In this work a dynamic cutting force model in ball end milling of inclined surface is introduced. To represent the complex cutting geometry in ball end milling of inclined surface, workpiece is modeled with Z-map method and cutting edges are divided into finite cutting edge elements. As tool rotates and vibrates, a finite cutting edge element makes two triangular sub-patches. Using the number of nodes in workpiece which are in the interior of sub-patches, instant average uncut chip thickness is derived. Instant dynamic cutting forces are computed with the chip thickness and cutting coefficients. The deformation of cutting tool induced by cutting farces is also computed. With iterative computation of these procedures, a dynamic cutting force model is generated. The model is verified with several experiments.

Measurement Technique of Cutting Temperatures Using Implanted Thermocouples in Ball End-Milling (볼 엔드밀링에서 열전대를 이용한 절삭온도 측정법)

  • Lee, Deuk-U
    • Transactions of the Korean Society of Mechanical Engineers A
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    • v.24 no.7 s.178
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    • pp.1748-1752
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    • 2000
  • In this paper, the measurement technique of cutting temperatures of shear zone using implanted thermocouples is proposed in ball end milling. K-type thermocouple implanted in the hole of workpieces is directly cut in order to measure temperatures of the shear zone in cutting process. Experiments are performed for a nickel based superalloy(Inconel 718) using a ball nose end mill. The results show that the cutting temperature in shear zone is about 3200C at the cutting speed of 90m/min with dry.

A Study on Deflection Model and Characteristics in Flexible Ball End Milling Process (유연성이 있는 볼 엔드밀 공구의 처짐 모델과 절삭성에 대한 연구)

  • 심충건;양민양
    • Transactions of the Korean Society of Mechanical Engineers
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    • v.15 no.3
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    • pp.1067-1082
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    • 1991
  • 본 연구에서는 비교적 강성이 약한 볼 엔드밀 공구에 있어서 처짐으로 인한 그 가공 특성을 알기 위하여, 변화된 칩 두께 및 처짐 모델로부터 절삭력을 예측하며 또한 절삭력에 의한 공구의 처짐으로 인하여 공구의 플랭크 부위와 공작물간의 발생하 는 간섭 특성을 고찰하고, 이러한 특성이 절삭성과 가공 오차에 미치는 영향을 실험을 통하여 분석하여 본다.

Verification System for Cutting Condition of Ball-End Milling Process (볼엔드 밀링의 절삭조건 검증시스템)

  • Kim, Chan Bong;Yang, Min Yang
    • Journal of the Korean Society for Precision Engineering
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    • v.12 no.2
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    • pp.123-134
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    • 1995
  • In this paper, the fast force algorithm has been studied so that it is used to calculate cutting forces and to develope the NC verification system. The NC verification using the fast force algorithm can verify excessive cutting force which is the cause of deflection and breakage of tool, and adjust the feed rate and spindle speed.

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A Study on Surface Roughness of Al alloy 7075 to Cutting depth in High-speed Machining (고속가공의 절삭 깊이에 따른 알루미늄 합금 7075의 표면 거칠기에 대한 연구)

  • Park, Eun-sik
    • Journal of the Korean Society of Manufacturing Process Engineers
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    • v.9 no.6
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    • pp.29-35
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    • 2010
  • Recently the industry high-speed machining has been applied to the automotive, aircraft, electronics parts machining because the effect of cost savings, machining time reduction and productivity improvement. In this study recently the aircraft structural aluminum alloy 7075 used in cutting the ball end-mill on the surface roughness terms most affect the parameters of the spindle speed and feed rate on the surface roughness of the work-piece according to the cutting depth is to investigate. Cutting depth at 0.3 mm has the lowest surface roughness.

Cornering and Feed-Rate Determination for Constant Max. Resultant Cutting Force with Ball-End Mill (볼 엔드밀 공구에 의한 코너가공과 일정한 최대 수평합력을 위한 이송속도 결정)

  • 조현덕;양민양
    • Transactions of the Korean Society of Mechanical Engineers
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    • v.15 no.5
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    • pp.1572-1586
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    • 1991
  • 본 연구에서는 볼 엔드밀 공구를 사용한 코너가공에서 절삭력을 예측하고, 가 공중 공구의 회전주기에 대한 최대 수평합력(max. resulant force)을 일정하게 유지시 키는 모델을 개발하고, 코너가공에 적용한다. 또 금형가공에는 절삭시간을 많이 소 요하여 생산성이 떨어지게 하는 주요한 원인이 되기 때문에 최대 수평합력을 황삭가공 에 적합하도록 설정하면 본 연구의 결과로 이송속도를 결정할 수 있다.

Determination of the Cutting Condition in High Speed-Machining Considering the Machining Efficiency (볼 엔드밀의 고속가공에서 가공능률을 고려한 가공조건의 선정)

  • 손창수;강명창;이득우;황경현
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 1997.04a
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    • pp.965-969
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    • 1997
  • Due to the high feed rate,high speed machining (HSM) provide a great potential of rationalization for the machining Dies and Moulds. But determination of cutting condition is very difficult, because cutting mechanism of high speed machining is very complicated,especially using ball end-mill. This paoer gives a report on selection of the optimal cutting condition to improve the machining efficiency, And optimal machining condition is determined through the cutting force, FFT analysis of cutting force and surface roughness according to the cutting condition. Based on this experiment result,wear process and machining characteristics are evaluated.

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A Study on the Wear Characteristics of the Ball End Mill According to the AlTiN Coated Layers (AlTiN 코팅 층수에 따른 볼 엔드밀의 마모특성에 관한 연구)

  • Cho, Gyu-Jae;Lee, Seung-Chul
    • Journal of the Korean Society for Precision Engineering
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    • v.27 no.8
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    • pp.54-61
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    • 2010
  • In this research KP-4, one of the plastic mold steels, was coated with the AlTiN from one layer to four layers by the PVD method in the $\Phi$ cemented carbide ball end mill. Coated KP-4 was processed with various conditions. For example, slope of $15^{\circ}$, $30^{\circ}$ and $45^{\circ}$ the spindle rotation speed was changed from 10,000rpm to 16,000rpm, the tool feeding speed was changed from 1,300mm/min to 1,700mm/min, the depth of cut was also changed from 0.3mm to 0.9mm, and etc. Cutting component force according to the coating layer number, surface roughness, and the wear of tool were studied.