The Influence Of Ball-end Cutter Spatial Orientation On The Milled Surface Roughness And Form Accuracy

In recent years,the influence of tool orientation on the quality of processed surface has received more and more attention in such industries as aerospace and aviation,automobile parts and various molds processing and manufacturing.Presently certain achievements have been made by domestic and foreign research on the relation between tool orientation and cutting quality.However,the existing research is directed at specific process system,and failed to completely establish the relation between cutting process and cutting mechanism.The research findings obtained currently are hard for direct application among different process system.Sometimes,the research conclusions have significant discrepancies even under the same processing condition.Controlling tool orientation can deliver higher form accuracy and roughness of surface to improve product's pre-determined performance and service life,improve product quality,guarantee use security of product,thereby further saving energy and reducing consumption,as well as enhancing enterprises' core competitive power.Based on existing research at home and abroad,the effect of multi-axis controlled change in tool orientation on cutting speed,cutting force and milling remain height is analyzed to predict the changes in roughness of surface,design and conduct multi-axis milling experiment for ball-end tools to verify the theoretical analysis.In multi-axis milling for free-form surfaces,the digitized model of free-form surfaces is designed to facilitate controlling of experiment parameters.Based on this,tool path for four-axis processing is planned.Finally the form errors for milling free-form surfaces are appraised using the matching score between processed surface point cloud and mathematical point cloud.The research finds that satisfactory roughness of surface and form accuracy can be achieved when primary inclination and banking angle of ball-end tool are around 50°(the lowest roughness was up to 0.58?m and the least average form error was 3.92?m in the experiment).The research findings can positively guide selection of tool orientation in multiaxis milling.