Analytical Calculation of Cutter/Workpiece Engagements for Helical Hole Milling

Author:

Wang Jue1,Yip-Hoi Derek2

Affiliation:

1. University of British Columbia, Vancouver, BC, Canada

2. Western Washington University, Bellingham, WA

Abstract

Helical milling is a 3-axis machining operation where a cutting tool is feed along a helix. This operation is used in ramp-in and ramp-out moves when the cutting tool first engages the workpiece, for contouring and for hole machining. It is increasingly finding application as a means for roughing large amounts of material during high speed machining. Simulating the helical milling process requires Cutter/Workpiece Engagement (CWE) geometry in order to predict cutting forces. The calculation of these engagements is challenging due to the complicated and changing intersection geometry that occurs between the cutter and the in-process workpiece. For hole milling an additional complication comes from self-intersections that occur with the tool swept volume. This makes the generation of the instantaneous in-process workpiece needed for finding the CWE difficult. In this paper we present an analytical approach for finding the engagement geometry that utilizes the intersection curves between a cylinder representing a flat end mill and the helicoidal surface generated by the bottom of the tool as it feeds downwards along the helix. This technique can be integrated into a solid modeler based approach for machining simulation. It has the advantage of not require instantaneous updates of the workpiece as is typically the case in finding CWEs.

Publisher

ASMEDC

Cited by 3 articles. 订阅此论文施引文献 订阅此论文施引文献,注册后可以免费订阅5篇论文的施引文献,订阅后可以查看论文全部施引文献

1. Mechanics and dynamics study of helical milling process for nickel-based superalloy;The International Journal of Advanced Manufacturing Technology;2019-12-19

2. Force prediction model for five-axis flat end milling of free-form surface based on analytical CWE;The International Journal of Advanced Manufacturing Technology;2018-08-16

3. Prediction of heat transfer process in helical milling;The International Journal of Advanced Manufacturing Technology;2014-02-25

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