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Indexed by:期刊论文

Date of Publication:2013-08-01

Journal:INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY

Included Journals:SCIE、EI、Scopus

Volume:67

Issue:9-12

Page Number:2853-2861

ISSN No.:0268-3768

Key Words:Form error; Sculptured surface; Ball-end milling; Tool deflection

Abstract:This paper presents an integrated form error compensation approach for ball-end milling of sculptured surface with z-level contouring tool path. From the analysis of local cutting equilibrium in general milling, an integrated form error compensation strategy is derived. In this strategy, the tool deflection is adopted as compensation value. The compensation value and local cutting equilibrium can be directly obtained from nominal cutting conditions; moreover, the time-consuming iterative process is no longer needed. The integrated strategy is then expanded to ball-end milling of sculptured surface based on the differential idea. A tool path modification model is also suggested to record the compensation value into tool path. A numerical example of comparing the calculation process of traditional multilevel compensation strategy and that of the integrated compensation strategy is described. The results of numerical examples show that the essentials of proposed integrated strategy and multilevel strategy are consistent, but the needed calculation steps of the two strategies are about 1 vs. 30. In the validation experiment, two practical sculptured surfaces are machined. Experimental results reveal that the integrated form error compensation approach can significantly reduce form error in ball-end milling of sculptured surface.