球形端銑刀銑削斜面之切削力分析模式

Analysis Model of Ball End Milling Forces for Inclined Plane Milling

陳政億(Cheng-Yi Chen)

指導教授 ： 蔡哲雄

國立臺北科技大學/機電學院/製造科技研究所/碩士(2006年)

https://doi.org/10.6841/NTUT.2006.00199

摘要

具曲面( Free form surface )的零件切削加工經常應用球形端銑刀( Ball end mill )作為精切削製程，其切削力的大小對於曲面模型的加工精度與粗糙度控制影響至大。然而，過去有關球形端銑刀切削力分析之探討，大多以水平面切削為主，少有對斜面或曲面進行研究。本文主要是以球形端銑刀銑削水平面之切削力分析為基礎，來建構球形端銑刀銑削斜面的切削力分析方法，提出球形端銑刀銑削斜面的三維切削力分析預測模式，包含球形端銑刀在斜面上爬升銑、下坡銑及水平移動銑削。
首先由斜面銑削實驗之數據及本文的切削力學模式，來獲得各項比切削參數(C 、C 、C )。接著驗證本文切削力模式，模擬球形端銑刀切削力與實驗量測值之精確度比較。最後提出在0°~45°的斜面間，進行球形端銑刀銑削之各種三維切削力預測，說明本文方法之應用。由實驗結果顯示，本文建構的球形端銑刀切削力分析方法，可有效的分析球形端銑刀銑削水平面及斜面之三軸向切削力。

關鍵字

球形端銑刀 ； 切削力模型 ； 斜面銑削

並列摘要

This paper proposes a mechanistic ball end mill cutting force model to estimate the ball end milling forces for inclined plane milling. The developed model that calculates the cutting forces based on a set of cutting force coefficients which depend on the material, the tool, the cutting conditions, the machining directions and the inclined angle of the milling surface. The developed ball end milling force models for inclined plane milling include rise milling ,downhill milling, and horizontal milling.
This study uses the present cutting force model and the measured ball end milling forces data to obtain equivalent specific cutting force coefficients (C , C , and C ) for some cutting conditions. By substituting the cutting force coefficients into the present ball end milling force model, the milling force variation both on horizontal plane and inclined plane can be predicted. Finally, the present study also construct some parametric Bezier surfaces of cutting force coefficients in the CAD system by using finite experiment data of ball end milling, which is used to easily find out the cutting force coefficients for any inclined angle of ball end milling operation. In the present study, the cutting force model has been tested on aluminum alloy Al7075-T6 with micro grain carbide ball end mill ( 10 - 2 flutes). Validation tests have been carried out on planar surfaces milling and on inclined plane milling in some typical ball end milling conditions. The results show that the predicted cutting forces agreed well with the measured cutting forces.

並列關鍵字

Ball end mill ； Cutting force model ； Inclined plane milling

參考文獻

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