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Ball End Mill, Milling Force Modeling And Finite Element Analysis

Posted on:2009-06-23Degree:MasterType:Thesis
Country:ChinaCandidate:W B ZhangFull Text:PDF
GTID:2191360248452562Subject:Mechanical Manufacturing and Automation
Abstract/Summary:PDF Full Text Request
In the present paper, a three dimensional milling force model for ball-nose end mill was established based on its the geometric model of cutting end edge. The influences of cutting edge angles on cutting force were analyzed. With the assist of the finite element software "ANSYS", real stress distribution, natural frequency and vibration mode were studied in the different milling conditions, such as cutting depth, the feed amount of each tooth, main shaft rotation and the extended length etc. The main conclusions are as following:1. Based on the geometric model and discretization of the milling cutting edge, the cutting of each discrete micro-unit could be considered as oblique cutting. A three dimensional model of milling force for ball-nose end mill was established by the cutting empirical equations. When the cutting parameters and milling circumstances are the same, the three dimensional milling composite force of the new cutting edge model presented by our university is smaller than that of the orthogonal spiral cutting edge.2. Introducing the emulation model of ball-nose end mill established by SolidWorks, the finite element analysis with the assist of ANSYS was done and some conclusions were obtained as follows. When the other cutting parameters keep constant, both the deformation and stress of ball-nose end mill increased with the cutting depth and their increasing amplitude and trend are nearly the same. Both the deformation and stress of ball-nose end mil! increase with the tooth feed amount and the stress increasing amplitude is more obvious. What's more, both the deformation and stress of ball-nose end mill increase with the main shaft rotation, and their increasing trend are the same while the amplitudes are different, and the deformation is much greater.3. The vibration mode analysis of emulation model of ball-nose end mill shows that: the first-order natural frequency and the second-order natural frequency of the cutter with the same extended length are similar, but the third-order and the fourth-order natural frequency, and the second-order and the third-order natural frequency are different. the natural frequency from first-order to fourth-order increase with the decreasing of the extended length. Under the condition of the same extended length the natural frequency of ball-nose end mill of sintered metal high speed steel (HSS) is lower than that of carbide ball-nose end mill, and the maximum deformation is contrary.
Keywords/Search Tags:ball-nose end mill, modeling, milling force, finite element analysis, modal analysis, ANSYS
PDF Full Text Request
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