Numerical simulation of chip ploughing volume in micro ball-end mill machining

作者：Luo Shan; Bayesteh Abdolreza; Ko Junghyuk; Dong Zuomin; Jun Martin B^*

来源：International Journal of Precision Engineering and Manufacturing, 2017, 18(7): 915-922.

DOI：10.1007/s12541-017-0108-2

• Micro machining
• Ball-end mill
• Ploughing volume
• Voxel
• Cutting forces

Chip ploughing becomes a more serious problem in micro-machining due to its relatively large size with respect to the finished part, negatively impacting on the accuracy of the finished surface. In this work, a 3D geometry model of the chips generated during micro ball-end milling is introduced to accurately calculate the chip ploughing volume to support needed tool path adjustments for ensured accuracy of the finished part. A new method is developed to compute the chip ploughing volume by dividing the modeled chip into many discrete pieces over a ploughing dominated region and a shearing dominated region. Two simulation methods for calculating the chip volume for two example tool paths are presented. Different axial depths of cut, spindle speed and feed rate are tested to study the ploughing mechanism and reduce the ploughing effects. Experiments of cutting force measurement are used to compare with the changes of the simulated ploughing and shearing volume.

• 出版日期2017-7