Wear Prediction of Ball End Mill during the Surface Milling Processes of Modified Composites

doi:10.3901/JME.2025.13.231

Abstract

Abstract: A novel wear prediction method of ball end mill is proposed for the surface milling processes of the heat-resistant modified composites manufactured by oblique winding and ablating processes (‘modified composites’ for short). The method not only respectively considers the actual stress states of the tool flank face and the cutting edge during the interaction with the workpiece, but also dynamically adjusts the wear coefficient and the tool surface hardness according to the dynamic state of force and temperature in the surface milling process. Through these ways, the accuracy of prediction results can be guaranteed completely. By experimental verification, it is found that the mean error of the prediction results is less than 15%. With the method, the tool wear law during the surface milling process of modified composites is analyzed. Results suggest that the cutting edge wear is related to rigidity of the cutting edge and the actual contact distance with the workpiece. To reduce the cutting edge wear, it is recommended to enhance the cutting edge rigidity by reducing the rake angle or the flank angle, or to reduce the actual contact distance by selecting low spindle speed or high feed rate. In terms of the flank face wear, it depends on the flank angle and the bouncing back height of the machined surface of workpiece. To reduce the flank face wear, milling the workpiece with the tool with large flank angle under high spindle speed or low feed rate is recommended. Since the strategies on reducing the cutting edge wear and reducing the flank face wear are contradictory, from a comprehensive perspective, it is suggested to adopt the strategy on reducing the cutting edge wear so that the wear extent of the whole tool can be suppressed more effectively.

Key words: modified composites, surface milling, wear prediction, wear law, ball end mil

CLC Number:

TH117

ZHANG Boyu, SUN Kai, MU Han, GUO Heyang, KONG Lingman, JIAN Xigao. Wear Prediction of Ball End Mill during the Surface Milling Processes of Modified Composites[J]. Journal of Mechanical Engineering, 2025, 61(13): 231-245.

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