Analysis Of Surface Location Error In The Process Of Inclined Plane Cutting With Ball End Milling

The main reason of Surface Location Error(SLE) during machining is the forced vibration of cutting system caused by periodic intermittent milling force. SLE has the direct effect to machining accuracy and surface quality. The main methods to reduce the SLE is optimizing cutting parameters, make it in harmony with the dynamic characteristics of the milling system. Based on the differential method, complex 3D surface can be seen as a series of tiny inclined plane combination. Therefore, the research on Surface Location Error of inclined plane in high speed milling process have important theoretical meaning and engineering value to explore the mechanism of high speed milling, and promote the further application of high speed milling technology.In this paper, research is carried out aim at the SLE during the process of inclined plane with ball end mill. First, A semi-analytical method is proposed to determine the Cutter Workpice Engagement(CWE),based on the CWE and the contact criterion, the effective cutting edge range is determined too. Then, according to cutting force model, the forces of inclined plane cutting process with ball end mill is acquired. Second, the researcher got the dynamic characteristics of cutting system through hammering test. And by simplify the tool workpiece system to a two degree of freedom spring-damping system, the milling dynamics model is established. Last, using the Complete Discretization Scheme(CDS), the researcher solve the dynamics differential equation and got the forced vibration condition, then got the SLE of inclined plane cutting process. The simulation of milling process was achieved and the predicted value of SLE is calculated by Matlab programming, and by comparing the predicted value and the result of inclined plane cutting experiment, the accuracy of the prediction is testified.This article discussed the SLE during the process of inclined plane with ball end mill, and provides a good foundation of subsequent research on 3D surface.