Ball ended milling cutters are extensively used in machining parts with sculptured surfaces. Milling of dies for forming, forging and injection plastic molding are most common operations in die shops. The dies are generally made of tool steels which are hard to machine. Breakage of tool shank and chipping of ball shaped helical flutes are the critical factors in ball end milling of die steels. In aerospace industry, aerodynamic sculptured shapes are milled with ball ended cutters. The aerospace parts are generally made of Titanium, Nickel and Aluminum alloys, and the dimensional accuracy and metal removal efficiency are critical factors in such operations. Ball end milling of compressor and turbine blades are typical operations in the aircraft engine industry. Mechanics of cutting with ball ended helical cutters are modeled. The model is based on the analytic representation of ball shaped helical flute geometry, and its rake and clearance surfaces. It is assumed that friction and pressure loads on the rake face are proportional to the uncut chip thickness area. The load on the flank contact face are concentrated on the in cut portion of the cutting edge. The pressure and friction coefficients are identified from a set of slot milling tests at different feeds and axial depth of cuts, and are used to predict the cutting forces for any cutting condition. The experimentally verified model accurately predicts the cutting forces in the three cartesian directions.


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    Title :

    Mechanics of ball end milling process


    Additional title:

    Mechanik des Fräsprozesses mit kugelförmigem Fräser


    Contributors:
    Yücesan, G. (author) / Altintas, Y. (author)


    Publication date :

    1993


    Size :

    9 Seiten, 7 Bilder, 14 Quellen



    Type of media :

    Conference paper


    Type of material :

    Print


    Language :

    English




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