Cutter-workpiece engagement calculation in 3-axis ball end milling considering cutter runout

Computing Cutter Engagement Values in Milling Tessellated Free-Form Surfaces

High speed milling (HSM) has great potential use in die/mold cutting, but traditional machining plans do exploit HSM capabilities effectively. An important consideration for in HSM is to limit cutting force variations, and one way to do so is to reduce Cutter-Workpiece engagement (CWE) variations. CWE is measured as the area of the tool instantaneously engaged with the part. Estimating CWE as a...

Dynamic Cutter Runout Measurement with Laser Sensor

The cutter runout is very common in machine milling and has a great effect on the surface accuracy. In this paper, a measurement of radial cutter runout in revolving milling tool is proposed by using the laser sensor. A laser beam is projected onto the milling tool edge and subsequently reflected. The diffuse reflection is captured by the sensor and the displacement between the cutter and the l...

Study of the effective cutter radius for end milling of free-form surfaces using a torus milling cutter

An Instantaneous Rigid Force Model For 3-Axis Ball-End Milling Of Sculptured Surfaces

An instantaneous rigid force model for prediction of cutting forces in ball-end milling of  sculptured surfaces is presented in this paper. A commercially available geometric engine is used to represent the cutting edge, cutter and updated part geometries. The cutter used in this work is an insert type ball-end mill. Intersecting an inclined plane with the cutter ball nose generates the cutting...

Correlation between machining direction, cutter geometry and step-over distance in 3-axis milling: Application to milling by zones

Computer-Aided Manufacturing (CAM) occupies an increasingly important role in engineering with all it has to offer in terms of new possibilities and improving designer/manufacturer productivity. The present study addresses machining of free-form surfaces on a 3-axis NCmachine tool. There have recently been a large number of studies devoted to planning tool paths on free-form surfaceswith variou...