CUTTING FORCE PREDICTION OF BALL END MILLING BASED ON FULLY VOXEL REPRESENTATION OF CUTTING EDGE AND INSTANTANEOUS WORKPIECE SHAPE
CUTTING FORCE PREDICTION OF BALL END MILLING BASED ON FULLY VOXEL REPRESENTATION OF CUTTING EDGE AND INSTANTANEOUS WORKPIECE SHAPE
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DOI：
10.1115/1.4038499
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发表时间：
2017-06
影响因子：
4
通讯作者：
Isamu Nishida;R. Okumura;R. Sato;K. Shirase
中科院分区：
文献类型：
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作者：
Isamu Nishida;R. Okumura;R. Sato;K. Shirase
开发了一种新的切削力模拟器，用于预测球头铣刀的切削力。在该模拟器中，基于代表刀具刃形和瞬时形状的全体素模型，离散地计算未切割切屑厚度。在以前的仿真器中，使用了一个工件体素模型来计算复杂形状变化下的未切割切屑厚度。使用工件体素模型，通过提取每个切削齿上去除的针对进给切削刃的材料量的体素来检测未切割切屑厚度。然而，由于刀具刃口的形状必须用数学表达式来定义，所以很难定义复杂的刃口形状。当刀具姿态变化不均匀时，也很难对刀具刃口去除的体素进行建模。为此，提出了一种新的切屑厚度检测方法，该方法用体素模型来完全描述切屑的刃口形状和瞬时形状。我们的新方法在微小的刀具旋转角度下精确地检测未切屑厚度，使得能够检测出介于复杂的工件表面形状和特定的刃口形状之间的未切屑厚度。为了验证新方法的有效性，利用球头立铣刀进行了五轴铣削实验。几种刀具姿势的估计磨削力被发现与测量的磨削力非常一致。五轴联动加工实验结果验证了该方法的有效性。
A new cutting force simulator has been developed to predict cutting force in ball end milling. In this simulator, uncut chip thickness is discretely calculated based on fully voxel models representing both cutting edge and instantaneous workpiece shape. In the previous simulator, a workpiece voxel model was used to calculate uncut chip thickness under a complex change of workpiece shape. Using a workpiece voxel model, uncut chip thickness is detected by extracting the voxels removed per cutting tooth for the amount of material fed into the cutting edge. However, it is difficult to define the complicated shape of cutting edge, because the shape of cutting edge must be defined by mathematical expression. It is also difficult to model the voxels removed by the cutting edge when tool posture is nonuniformly changed. Therefore, a new method to detect uncut chip thickness is proposed, one in which both cutting edge and instantaneous workpiece shape are fully represented by a voxel model. Our new method precisely detects uncut chip thickness at minute tool rotation angles, making it possible to detect the uncut chip thickness between the complex surface shape of the workpiece and the particular shape of the cutting edge. To validate the effectiveness of our new method, experimental five-axis milling tests using ball end mill were conducted. Estimated milling forces for several tool postures were found to be in good agreement with the measured milling forces. Results from the experimental five-axis milling validate the effectiveness of our new method.