Ball-end Cutter Modeling And Milling Force Simulation In Virtual NC Milling

Virtual NC machining is the technology which maps the NC machining processmap into the virtual environment and simulates the working process of the numericalcontrol equipment and working environment. With the further research on the virtualmanufacturing technology, virtual NC machining technology, one of the importantresearch directions in virtual manufacturing, has also developed rapidly. Ball-endmilling cutter modeling and milling force simulation play a key role in the NCmilling simulation, the research can provide critical data for the product machiningprocess and have an important guidance significance.The paper aims to take the NC milling machining as the research object with anintensive study of ball-end cutter modeling and milling force simulation for the NCmilling machining. Firstly, based on the common characteristics of rotary millingcutter, the mathematical model of edge curve for the ball-end cutter is deducedthrough the universal formula of the blade curve; According to the feature of thehead of ball-end milling cutter, the general mathematical formula of the spiral facefor cutter head is created, and three-dimensional sold model of ball-end milling cutteris set up which can provide effective geometry for the physical simulation, geometricsimulation and physical simulation are judiciously combined. With the analysis ofthe relationship among scraps thickness, cutting micro-unit arc long and the millingforce, the milling force modeling is established taking physical factors intoconsideration, such as spindle eccentricity, cutter deformation, and vibration andmilling temperature with the method of principal components analysis to identify themilling force coefficients. Finally, based on milling force modeling, a virtual NCmachining milling force simulation system is developed with the hybridprogramming of VC++and MATLAB as well as the use of interface technology toconnect and call database. Through comparing and analyzing the results of themilling force and simulation results of the system, a conclusion is drawn that it is quite necessary to consider considering comprehensive physical factors during theresearch of the milling force; at the same time, it also proves the rationality of themilling force modeling.The rationality and stability of system model are verified by milling forceexperiments, and this system provides theoretical basis for the actual productionprocessing, so that quality can be guaranteed, efficiency can be improved and cost isreduced.