Skip to main content
SpringerLink
Log in

Effect of geometric feature and cutting direction on variation of force and vibration in high-speed milling of TC4 curved surface

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Curved surface parts with difficult-to-machine material are widely used in the industrial applications, and the three-axis NC machining with ball-end cutter is the commonly adopted method for some simple curved surface parts machining due to its high stiffness and simple operation. Due to the geometric feature variation for the curved surface and the bigger cutting force of the difficult-to-machine material, the cutting area and the cutting speed are changing all the time along the determined tool-path which results in a severe variation of cutting force and cutting vibration in high-speed milling process. This may not only affect the machining quality but also the tool life. In this way, the effect of the geometric feature of the curved surface and the cutting direction along the tool-path on the variation of force and vibration in high-speed milling of TC4 curved surface is studied. The experimental results show that both the cutting force and the cutting vibration increase when the tool-path curvature radius increases, while the cutting force decreases when the effective cutting radius increases and the cutting vibration will increase many times when the cutting area increases. Besides, the uphill cutting method for curved surface machining can obtain good machining quality and prolong milling cutter life. It can provide guidance for machining strategy selection especially for the cutting direction selection in the tool-path planning. The achievement, that can make both cutting force and cutting vibration small based on the geometric feature and the cutting direction, provides guidance for the machining planning of TC4 curved surface, which leads to improving machining quality and reducing tool wear.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Patrikalakis NM, Maekawa T (2002) Shape interrogation for computer aided design and manufacturing. Springer 32(2): 341–352

  2. Lasemi A, Xue D, Gu P (2010) Recent development in CNC machining of freeform surfaces: a state-of-the-art review. Comput Aided Des 42(7):641–654. https://doi.org/10.1016/j.cad.2010.04.002

    Article  Google Scholar 

  3. Cheng YM, An S, Zhang Y, Li HC (2013) Discussion and analysis on the NC machining tool path planning of aeroengine complex surface parts. J Harbin Univ Sci Technol 5(18):30–36

    Google Scholar 

  4. Hauth S, Richterich C, Glasmacher L, Linsen L (2011) Constant cusp toolpath generation in configuration space based on offset curves. Int J Adv Manuf Technol 53(1):325–338. https://doi.org/10.1007/s00170-010-2817-x

    Article  Google Scholar 

  5. Suresh K, Yang DCH (1994) Constant scallop-height machining of free-form surfaces. J Eng Ind 116(2):253–259. https://doi.org/10.1115/1.2901938

    Article  Google Scholar 

  6. Chiang ST, Tsai CM, Lee AC (1995) Analysis of cutting forces in ball-end milling. J Mater Process Technol 47(3):231–249. https://doi.org/10.1016/0924-0136(95)85001-5

    Article  Google Scholar 

  7. Fan X, Loftus M (2009) A simplified cutting force model for light-cut ball-end milling applications. Mach Sci Technol 13(1):52–75. https://doi.org/10.1080/10910340902776077

    Article  Google Scholar 

  8. Zeroudi N, Fontaine M (2015) Prediction of tool deflection and tool path compensation in ball-end milling. J Intell Manuf 26(3):425–445. https://doi.org/10.1007/s10845-013-0800-8

    Article  Google Scholar 

  9. Naserian RS, Sadeghi MH, Haghighat H (2007) Static rigid force model for 3-axis ball-end milling of sculptured surfaces. Int J Mach Tools Manuf 47(5):785–792. https://doi.org/10.1016/j.ijmachtools.2006.09.014

    Article  Google Scholar 

  10. Azeem A, Feng HY, Wang L (2004) Simplified and efficient calibration of a mechanistic cutting force model for ball-end milling. Int J Mach Tools Manuf 44(2–3):291–298. https://doi.org/10.1016/j.ijmachtools.2003.09.007

    Article  Google Scholar 

  11. Hu HJ, Zhai ZY, Wang H, Dai JL (2015) Researches on physical field evolution of micro-cutting of steel H13 by micron scale ceramic cutter based on finite element modeling. Int J Adv Manuf Technol 78(9–12):1407–1414

    Article  Google Scholar 

  12. Boyd JM, Hosseinkhani K, Veldhuis SC, Ng E (2016) Improved prediction of cutting forces via finite element simulations using novel heavy-load, high-temperature tribometer friction data. Int J Adv Manuf Technol 86(5–8):2037–2045. https://doi.org/10.1007/s00170-015-8284-7

    Article  Google Scholar 

  13. Chen WF, Chen CK, Lai HY (2002) Design and NC machining of concave-arc ball-end milling cutters. Int J Adv Manuf Technol 20(3):169–179. https://doi.org/10.1007/s001700200140

    Article  Google Scholar 

  14. Chen WY, Chang PC, Liaw SD, Chen WF (2005) A study of design and manufacturing models for circular-arc ball-end milling cutters. J Mater Process Technol 161(3):467–477. https://doi.org/10.1016/j.jmatprotec.2004.07.086

    Article  Google Scholar 

  15. Qi CX, Jiang B, Zheng ML, Yang YJ, Sun P (2011) Research on instantaneous cutting force of high speed ball-end milling cutter. Adv Mater Res 188:277–282. https://doi.org/10.4028/www.scientific.net/AMR.188.277

    Article  Google Scholar 

  16. Irene BC, Joan VC, Alejandro DF (2012) Surface topography in ball-end milling processes as a function of feed per tooth and radial depth of cut. Int J Mach Tools Manuf 53(1):151–159

    Article  Google Scholar 

  17. Zhang ST, Ma MY, Fu L, Zhao H, Zhou X (2016) The method of simulation analysis of machining techniques about complex curved surface. Procedia CIRP 56:620–624. https://doi.org/10.1016/j.procir.2016.10.122

    Article  Google Scholar 

  18. Salami R, Sadeghi MH, Motakef B (2007) Feed rate optimization for 3-axis ball-end milling of sculptured surfaces. Int J Mach Tools Manuf 47(5):760–767. https://doi.org/10.1016/j.ijmachtools.2006.09.011

    Article  Google Scholar 

  19. Kang MC, Kim KK, Lee DW, Kim JS, Kim NK (2001) Characteristics of inclined planes according to the variations of cutting direction in high-speed ball-end milling. Int J Adv Manuf Technol 17(5):323–329. https://doi.org/10.1007/s001700170166

    Article  Google Scholar 

  20. Zhang S, Li JF (2010) Tool wear criterion, tool life, and surface roughness during high-speed end milling Ti-6Al-4V alloy. J Zhejiang Univ Sci A (Appl Phys Eng) 11(8):587–595. https://doi.org/10.1631/jzus.A0900776

    Article  Google Scholar 

  21. Yang SC, Cui XY, Zhang YH, Wang ZW (2016) Effect of tool wear on surface qualities in milling of TC4. Mater Sci Forum 836-837:132–138. https://doi.org/10.4028/www.scientific.net/MSF.836-837.132

    Article  Google Scholar 

  22. Wu WH, Chen WM, Wang XH, Zhao C (2012) Influence of cutting parameters and tool geometric angles on TC4 titanium alloy chip shape. Adv Mater Res 490-495:3912–3915. https://doi.org/10.4028/www.scientific.net/AMR.490-495.3912

    Article  Google Scholar 

  23. Huang PL, Li JF, Sun J, Zhou J (2013) Study on vibration reduction mechanism of variable pitch end mill and cutting performance in milling titanium alloy. Int J Adv Manuf Technol 67(5–8):1385–1391. https://doi.org/10.1007/s00170-012-4575-4

    Article  Google Scholar 

Download references

Acknowledgements

The authors wish to thank the anonymous reviewers for their comments which led to improvements of this paper.

Funding

This work was supported by the National Natural Science Foundation of China (Grant No. 51575087 and No. 51675081), National Science and Technology Major Project of China (Grant No. 2016ZX04001-002), Innovation Project for Supporting High-level Talent in Dalian (Grant No. 2016RQ012), Science Fund for Creative Research Groups (Grant No. 51621064), and the Fundamental Research Funds for the Central Universities (Grant No. DUT17LAB13).

Author information

Authors and Affiliations

  1. Key Laboratory for Precision and Non-traditional Machining Technology of the Ministry of Education, School of Mechanical Engineering, Dalian University of Technology, Dalian, 116024, China

    Jian-wei Ma, Guo-qing Hu, Zhen-yuan Jia, Ning Zhang & Fu-ji Wang

Authors
  1. Jian-wei Ma
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Guo-qing Hu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Zhen-yuan Jia
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Ning Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Fu-ji Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jian-wei Ma.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Ma, Jw., Hu, Gq., Jia, Zy. et al. Effect of geometric feature and cutting direction on variation of force and vibration in high-speed milling of TC4 curved surface. Int J Adv Manuf Technol 95, 2207–2218 (2018). https://doi.org/10.1007/s00170-017-1388-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-017-1388-5

Keywords

Search

Navigation