Prediction of Surface in Machining by Flat and Spherical Surface Tools

Document Type: Persian

Authors

1 Assouiate Professor, Mechanical Engineering Dept., Sharif University

2 M.Sc., Mechanical Engineering Dept., Sharif University

Abstract

In this paper, the profile of surfaces machined using end mills with flat and ball end tools in modeled. The real kinematics of the tool motion, the static deflection and the run out of the tool are included in the model. The cutting forces are calculated using a semi-empirical method based on orthogonal to oblique conversion of cutting coefficients. The thickness of the uncut chip is used as the critical parameter affected by the tool run out. Based on the above model, the final profile of the surface is generated and compared with existing experimental results

Keywords


[1]            S. Smith, J. Tlusty, An Overview Of Modeling and Simulation Of The Milling Process, J. of Eng. For Industry, Vol. 113, 1991,pp. 169

[2]            M. Martellotti, An Analysis Of Milling Process, Part 2: Down-Milling, Transactions Of The ASME, Vol. 67, 1945, pp. 233

[3]            M. Martellotti, An Analysis Of Milling Process, Transactions Of The ASME, Vol. 63, 1941, pp. 667

[4]            Y. Mizugaki, and K. Kikkawa, Geometric Generating Mechanism Of Machined Surface By Ball-Nosed End Milling, Annals Of The CIRP, Vol. 50, No. 1, 2001, pp. 69

[5]            Ee Meng Lim, His Feng , The Prediction Of Dimensional Error For Sculptured Surface Productions Using The Ball-End Milling Process. Part 1: Chip Geometry Analysis And Cutting Force Prediction, Int. J. Mach. Tools Manufact., Vol. 35, No. 8, 1995, pp. 1149

[6]            G. Yucesan, and Y. Altintas, Prediction Of Ball End Milling Forces, J. Engineering For Industry, Vol. 118, 1996, pp.95

[7]            B. Ikua, and H. Tanaka, Prediction Of Cutting Force And Machining Error In Ball End Milling Of Curved Surfaces. 1-Theoretical Analysis, Int. J. Of Precision Engineering, Vol. 25, 2001, pp. 266

[8]            Y. Altintas, and P. Lee, Mechanics And Dynamics Of Ball End Milling, Transactions Of ASME, Vol. 120, 1998, pp. 684

[9]            Y. Altintas, and P. Lee, Prediction Of Ball –End Milling Forces From Orthogonal Cutting Data, Int. J. Mach. Tools Manufact., Vol. 36, No. 9, 1996, pp. 1059

[10]        F. Ismail, and M. A. Elbastawi, Generation Of Milled Surfaces Including Tool Dynamics And wear, Int. J. Of Engineering For Industry, Vol. 115, 1993, pp. 245

[11]        F. Ismail, and M. A. Elbastawi, Surface Topography Characterization In Finish Milling, Int. J. Mach. Tools Manufact., Vol. 34, No. 2, 1994, pp. 245

[12]        W. A. Kline, and R. E. Devor, The Effect Of Runout On Cutting Geometry And Forces In End Milling, Int. J. Mach. Tools Manufact., Vol. 23, No. 2/3, 1983, pp. 123