• Transactions of the Korean Society of Machine Tool Engineers
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• v.12 no.2
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• pp.44-52
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• 2003

This research suggests a cutting force model for the ball end milling processes. This model includes the effect of tool run out and tool deflection. In the proposed model, the flutes of ball end mills are considered as series of infinitesimal elements and each cutting edge is assumed to be straight for the analysis of the oblique cutting process, in which the small cutting edge element has been analyzed as an orthogonal cutting process n the plane including the cutting velocity and the chip-flow vector. Therefor, the cutting forces can be calculated through the model using the orthogonal cutting data obtained from the orthogonal cutting test. In order to enhance the performance of the model, the flutes of ball end mill are defined to keep geometric consistency at the peak of the ball part and the junction with the end mill part. The divided infinitesimal cutting edges are regulated to be even lengths. Some experiments show the validity of the developed model in the various cutting coalitions.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.245-250
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• 2003

This research conducted milling tests to study effects of cutting environment conditions of ball end mills on the characteristics of hard milling process. KP4 steels and STD11 heat treated steels were used as the workpiece and WC-Co ball end mill tools with TiAIN coated were utilized in the cutting tests. Dry cutting without coolant and semi-dry cutting using botanical oil coolant were conducted and MQL (Minimum Quantity Lubricant) device was used to spray coolant. Cutting forces, tool wear and surface roughness were measured in the cutting tests. Results showed that dry cutting of KP4 and hardened STD11 specimens produced better surface quality and wear performance than MQL spray cutting did.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.3 s.180
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• pp.39-46
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• 2006

In this work a dynamic cutting force model in ball end milling of inclined surface is introduced. To represent the complex cutting geometry in ball end milling of inclined surface, workpiece is modeled with Z-map method and cutting edges are divided into finite cutting edge elements. As tool rotates and vibrates, a finite cutting edge element makes two triangular sub-patches. Using the number of nodes in workpiece which are in the interior of sub-patches, instant average uncut chip thickness is derived. Instant dynamic cutting forces are computed with the chip thickness and cutting coefficients. The deformation of cutting tool induced by cutting farces is also computed. With iterative computation of these procedures, a dynamic cutting force model is generated. The model is verified with several experiments.

• Transactions of Materials Processing
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• v.13 no.1
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• pp.45-52
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• 2004

This research conducted milling tests to study effects of cutting environment conditions of ball end mills on the characteristics of hard milling process. KP4 steels and STD11 heat treated steels were used as the workpiece and WC-Co ball end mill tools with TiAlN coated were utilized in the cutting tests. Dry cutting without coolant and semi-dry cutting using botanical oil coolant were conducted and MQL(Minimum Quantity Lubricant) device was used to spray coolant. Cutting forces, tool wear and surface roughness were measured in the cutting tests. Results showed that dry cutting of KP4 and hardened STD11 specimens produced better surface quality and wear performance than MQL spray cutting did.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1999.10a
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• pp.591-596
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• 1999

Due to the development of CNC machining centers and the complexity of machined part geometry, the ball-end milling became the most widely used the cutting process. Generally, the tool runout defined as the eccentricity of a rotating tool set in the holder involved the spindle runout and the problem of tool runout generated to remove the workpiece is a main factor affecting the machining accuracy. In this paper, the relationship of tool runout(zero-to-peak, P-K) and surface shape on the change of cutting conditions is studied and it is proposed the probability of prediction of surface shape from the in-process tool runout measurements with high response displacement sensor in the ball-end milling

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.7 s.178
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• pp.1748-1752
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• 2000

In this paper, the measurement technique of cutting temperatures of shear zone using implanted thermocouples is proposed in ball end milling. K-type thermocouple implanted in the hole of workpieces is directly cut in order to measure temperatures of the shear zone in cutting process. Experiments are performed for a nickel based superalloy(Inconel 718) using a ball nose end mill. The results show that the cutting temperature in shear zone is about 3200C at the cutting speed of 90m/min with dry.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.10a
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• pp.238-244
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• 2004

This research conducted milling tests to study effects of cutting environment conditions of ball end milts on the characteristics of high speed milling cutting process. KP4 steels and STD11 heat treated steels were used as the workpiece and WC-Co ball end mill tools with TiAIN coated were utilized in the cutting tests. Dry cutting without coolant and semidry cutting using botanical oil coolant by the MQL(Minimum Quantity Lubricant) device were conducted. Cutting forces, tool wear and surface roughness were measured in the cutting tests. Results showed that MQL spray cutting of KP4 and hardened STD11 specimens produced better surface quality and wear performance than dry cutting did.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.10
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• pp.35-44
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• 1999

The performance of interrupted cutting operations like milling is consideraly affected by cuter runout. In this study, cutter runout is selected as an important machining parameter for evaluation of machinability in ball-end milling and caused from misalignments of tool and holder, unbalanced mass of parts and tool deflection under machining. To evaluate the machinability due to cutter runout, the rotating accuracy of spindle, cutting force and surface roughness are measured. The rotating characteristics of spindle in each revolution speed were investigated by cutter runout in freeload. The predicted surface form of workpiece by measuring cutter runout data was compared with real surfaces. The results show that measuring runout with high response gap sensor is useful for studying the phenomenon of high-speed machining and the monitor surface form using in-process runout measurements in ball-end milling is possible.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2010.05a
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• pp.221-222
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• 2010

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2009.06a
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• pp.461-462
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• 2009