Study On The Cutting Force Modeling And Machined Surface Topography Simulation In Ball-end Milling Process

Advanced machining technology is the foundation of the national-defense and industry modernization and is a key criterion to evaluate the manufacturing level of a country. Ball-end milling is widely used in die/mould, automobile and aerospace industries, in order to reduce the cost and save time during the manufacturing process, it is worthwhile to develop research on the milling process simulation.Combining with the development of the advanced machining technology, based on the foundational theory of the cutting process, this paper carry out research on the modeling of cutting force prediction and surface topography simulation during ball-end milling process.Cutting force is an important parameter in the physical simulation of milling; it is the foundation of the tool-workpiece deformation calculation and the dynamic simulation of cutting system. Considering the runout of the cutter, the undeformed chip thickness was expressed mathematically. Axial-discretization was employed to denote the cutting edge and the geometrical analysis method was used to determine the engagement of the cutting edge element. The force model was established based on the empirical chip-force relationship and integrated along the cutting edge. The nominal cutting force was introduced to solve the cutting coefficient with the elimination of runout effect. This proposed model has the advantage of determining the cutting edge engagement simply and rapidly and few experiments are required to solve the cutting coefficients.In milling process, surface topography is a significant factor that affects directly the surface integrity and constitutes a supplement to the form error associated with the workpiece deformation. Based on the tool paths of the multi-axis NC machining and the trajectory equation of the cutting edge relative to the workpiece, the topographysimulation models of both the C~0 and C~1 continuous paths are established, then anew and general iterative algorithm is developed here for the numerical simulation of the machined surface topography in multi-axis ball end milling. The influences of machining parameters such as the feedrate, milling modes, cutter runout, cutter inclination direction and cutter inclination angle upon the topography and surface roughness values are studied in detail. Simulation and experiments have done on the plane milling and cylindrical milling process, the comparison between these predicted...