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.
The International Journal of Advanced Manufacturing Technology – Springer Journals
Published: Nov 21, 2017
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