• Design & Manufacturing
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• v.17 no.1
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• pp.33-39
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• 2023

The ball end mill is a type of cutting tool that is widely used to process complex mold shapes including aspheric surfaces. Unlike the flat end mill in which the cutting edge is formed on the cylindrical handle, the cutting edge is formed from the cylindrical handle to the hemispherical shape, which is advantageous for processing curved shapes. However, since the cutting speed continuously changes during machining due to the helix angle of the cutting edge or the machining inclination angle, it is difficult to obtain a precise machined surface. Therefore, in this paper, machining was performed while changing the helix angle of the ball end mill and the angle of the machining slope under the same cutting conditions for STD 11 material, which is widely used as a mold material. Through this, the effect of the two variables on the roughness of the machined surface was analyzed. As a result, if the helix angle was 0 degrees, it showed the best surface roughness of Ra. 0.16 ㎛. When the helix angle was 20 degrees, the best surface roughness of Ra. 0.18 ㎛ was occurred.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.04a
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• pp.167-172
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• 2003

The machining method by using end-milling tool has been applying in machining structures of various shapes because of the availability. Recently, all kinds of industries based on the parts of micro shape are developing, and the demands of mechanical micro machining technology are Increasing suddenly to produce these parts. According to such changes, the technology of the micro end-milling machining is applying as one of the most important machining means. This research is to aim at developing machining technology for various micro structures using micro end-mill. This paper introduces micro mechanical machining system with ultra precision, and demonstrates methods manufacturing all sorts of parts and moldings for industry and examples of applicable machining by using micro end-milling tool of micro sizes from hundreds to tens in diameter.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.05a
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• pp.1001-1004
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• 2000

As tools for machining precision components, end mills and ball end mills are widely used. For the end mills have longer cylindrical shape comparing diameter, liable to deflect and induce deterioration of surface roughness. Tool geometry parameters and cutting process have complex relations with each other. So, It is hard to determine hew to select optimal tool geometry. So, to improve the stiffness, relationship between cutting process and tool geometry must be studied. In this study, relations between grinding wheel geometry, setting condition and tool geometry are revealed. For the purpose of studying relations between each parameter, the equivalent diameter of tool has been calculated assuming tool as a simple beam. By the various cutting simulations and experiments, tool geometry and cutting process has been studied.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.6
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• pp.43-51
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• 2004

A method for form error prediction in side wall machining with a flat end mill is suggested. Form error is predicted directly from the tool deflection without surface generation by cutting edge locus with time simulation. Developed model can predict the surface form error about three hundred times faster than the previous method. Cutting forces and tool deflection are calculated considering tool geometry, tool setting error and machine tool stiffness. The characteristics and the difference of generated surface shape in up milling and down milling are discussed. The usefulness of the presented method is verified from a set of experiments under various cutting conditions generally used in die and mold manufacturing. This study contributes to real time surface shape estimation and cutting process planning for the improvement of form accuracy.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.2
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• pp.257-266
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• 1993

Computer Simulation based of divided element method was done to predict strip shape in20-high Sendzimir Mill and has been used to find a way for preventing quarter waves occurring in the wide and thin gaged strip rolling. The simulation showed that it was difficult to prevent quarter waves by the existing methods of controlling actuators such as the shifting of the first intermediate roll and the profile control of As-U-Roll in back up roll. It was, however, confirmed analytically and experimentally that quarter waves could be effectively reduce by changing taper mode at the barrel-end taper radius of the first intermediate roll.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.24 no.5
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• pp.508-513
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• 2015

In this study, the effect of the helix angle and rake angle of a flat end-mill in the milling of titanium alloy was investigated. Tool shape parameters such as helix angle and rake angle affect the cutting force, cutting zone temperature, vibration, and chip flow mechanism, which in turn determine tool life, surface integrity, and dimensional accuracy of the milling process. To investigate the effect of the helix and rake angles, a certain range of parameters was selected, and three-dimensional tool models were generated for finite element analysis (FEA) for each case. The cutting force and pressure on the tool flank face and rake face were investigated by FEA. Further, several tool models were proposed for machining tests. The cutting force characteristics were investigated by the machining tests.

• Transactions of the Korean Society of Mechanical Engineers
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• v.9 no.4
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• pp.440-451
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• 1985

This study is concerned with the analysis of cutting force system acting on ball-nose end mill in three-dimensional surface machining process. Conical tipped circular cutting edge element model and free surface machining process types are proposed to apply oblique cutting theory, and then derived equations are used for numerical approach of cutting force curves by matrix method. This approach has a good agreement with experimental results both in magnitude and shape within the range of 15 percent, which was conformed on 6061-T6 aluminum workpiece having twofold curvatured surface. From the cutting load variation to edge location, it is confirmed that circular cutting edge shapes has a better cutting ability than that of straight and both have a singularity near a tool point. It is also verified that what kind of machining condition is recommendable for three-dimensional machining process in connection with deflection of the cutter to workpiece and tool point wearing or system stability.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.1
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• pp.39-44
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• 2014

Techniques of tool posts are developing such that variable machining is possible using only one machine for the complication of a product's shape and to reduce the machining time. In order to develop a mill turret with a variable machining function with the mounting of mill turret units on a B-axis tilting table, we determine the static/dynamic stability of the structure of the mill turret. To this end, a static structural analysis and a modal analysis were conducted. From the results of the static structural analysis, the maximum stress was found to be less than the allowable stress. By the comparing the results of the modal analysis of the excitation frequencies of the mill turret, there were no resonance regions found. Therefore, the mill turret with the B-axis tilting facility is shown to have good structural integrity.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.3
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• pp.15-20
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• 2016

In this study, a numeric model for the prediction of ideal surface roughness in the rounded end mill was derived from the shape of the tool and feed per tooth. The model is compared with the well-known model of a ball and flat end mill. The ideal surface roughness was matched to the actual surface roughness by the linear equation, from which the empirical constant should be gathered from the test machining systems in the industry.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.04a
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• pp.354-358
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• 2004

There was not the evident analysis about the cutting process of CNC machining, and wouldn't be difficult to estimate the result of machining for the various cutting conditions. Therefore they were not founded the systemic technology about the optimum cutting conditions and selection of cutting tools. So this study have investigated the common facts for needs through the end-mill cutting machining by Machining-Centers or High-speed cutting machines, and developed the user-centered intelligent decision system to selection of the methodology about cutting conditions to improve the machining efficiency of end-mill cutting process.