Modeling on Static Milling Force of Ball-end-milling Cutters Based on Semi-analytical Method

doi:10.3901/JME.2022.11.282

Abstract

Abstract: A semi-analytical modeling method for static milling force of ball-end-milling cutter is proposed. Based on the principle of homogeneous coordinate transformation, a ball-end-milling cutter tooth trajectory equation considering cutter jesture adjustment is established. A spherical surface is used to replace swept surface by the cutter tooth, the identification of instantaneous engagement area between cutter and workpiece (cutter-workpiece engagement area for short) in milling process is transformed into three boundary lines and three intersections. Based on the inverse transformation principle of homogeneous coordinate, a semi-analytical method for solving cutter-workpiece engagement area is proposed. Newton-raphson numerical method is used to calculate the intersection point between the reference line and the actual swept surface, and the instantaneous undeformed chip thickness is obtained. Based on the improved mechanical modeling method, the micro-element milling force is derived, and the micro-element milling force is converted to the spindle servo coordinate system by the principle of homogeneous coordinate transformation, and the instantaneous static milling force is obtained by the integral method. In the cutting force validation test, it is shown that the proposed method can effectively predict the milling force and has higher computational efficiency than the improved Z-MAP method.

Key words: ball-end-milling, milling force, cutter-workpiece engagement erea, undeformed chip thicknes, semi-analytical method

CLC Number:

TH161
TG54

DONG Yongheng, LI Shujuan, ZHANG Qian, HONG Xiantao, LI Pengyang, LI Qi, LI Yan. Modeling on Static Milling Force of Ball-end-milling Cutters Based on Semi-analytical Method[J]. Journal of Mechanical Engineering, 2022, 58(11): 282-294.

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