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论文类型：期刊论文

第一作者：Wei, Z. C.

通讯作者：Wei, ZC (reprint author), Dalian Univ Technol, Sch Mech Engn, Dalian 116024, Peoples R China.

合写作者：Wang, M. J.,Cai, Y. J.,Wang, S. F.

发表时间：2013-09-01

发表刊物：INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY

收录刊物：SCIE、EI、Scopus

卷号：68

期号：5-8

页面范围：1167-1177

ISSN号：0268-3768

关键字：Ball-end mill; Cutting force; Feed direction; Z-map; Cutter engagement

摘要：This paper presents an approach for prediction of cutting forces in three-axis ball-end milling of a sculptured surface along an arbitrary tool path. The idea of differentiation is adopted to deal with the problems of varying feed direction, varying cutter engagement, and the consequent varying cutting forces in sculptured surface machining. Based on the differential idea, the whole process of sculptured surface milling is discretized at intervals of feed per tooth, and each segmented process is considered as a small steady-state cutting. For the discrete cuttings, mathematical models of feed turning angle and feed inclination angle are proposed according to the position of start/end points. By using an improved Z-map method, the detailed algorithms of determining the cutter-workpiece interface and the instantaneous in-cut edge segment for sculptured surface machining are suggested. A new integrative chip thickness model which involves the effects of feed turning angle, feed inclination angle, and cutter engagement is also presented. In validation experiment, two practical examples of a sculptured surface three-axis ball-end milling with arbitrary tool path are operated. Comparisons of the predicted cutting forces with the measurements show the effectiveness of the proposed approach.