期刊
JOURNAL OF MANUFACTURING PROCESSES
卷 75, 期 -, 页码 219-231出版社
ELSEVIER SCI LTD
DOI: 10.1016/j.jmapro.2021.12.059
关键词
Ball -end milling; Free-form milling; Roughness; Surface topography; Tooltip
资金
- Coordenacao de Aperfeicoamento de Pessoal de Nivel Superior -Brasil (CAPES) [001]
- Fundacao de Amparo a Pesquisa do Estado de Sao Paulo -Brasil (FAPESP)
- Fundacao de Amparo a Pesquisa do Estado de Santa Catarina -Brasil (FAPESC)
- Conselho Nacional de Desenvolvimento Cientifico e Tecnologico -Brasil (CNPq)
- [PID PDC2021-121792-I00]
This paper investigates the effects of tool-surface engagement on the finishing of workpieces in free-form milling. The study identifies two cutting mechanisms, Tip-On and Tip-Out, and quantifies the impact of accumulated cutting energy and tool-surface engagement on roughness.
This paper explains and quantifies the effects of the tool-surface engagement (TSE) on the workpiece finishing when using a ball-end tool in free-form milling of metallic mold materials with distinct elastoplastic responses. Electrolytic copper and AISI H13 steels were machined under different TSE and monitored for Sz roughness and cutting energy. As a result, two different cutting mechanisms named Tip-On and Tip-Out were identified. In Tip-On, the tooltip directly contributes to the part final surface formation, while at Tip-Out the tooltip only takes part of the chip removal without participating in the part surface generation. Accumulated cutting energy during every chip formation was also calculated based on machining force measured experimentally. With accumulated cutting energy 10 times lower than down-milling, the up-milling mode improved the part roughness by 43% at the Tip-Out mechanism. Contrary, down-milling produced four main surface damages due to the higher accu-mulated cutting energy, i.e., plastic deformation and side flow in ductile parts and cavities and scratches in harder workpieces. Real Sz roughness was 7 to 19 times higher than the theoretical one with major influences of the TSE and workpiece material. In conclusion, hand finishing can be reduced by applying up-milling and Tip-Out strategies when milling free-forms of harder workpieces.
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