A Study on End Milling of Hardened Steel. (3rd Report). A Prediction Model of Cutting Forces for Ball End Mills and Control for Constant Cutting Forces Using this Model.

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  • 焼入鋼のエンドミル加工に関する研究　（第３報）　　ポールエンドミルの切削抵抗の簡易推定式とそれによる切削抵抗の一定化制御
  • ヤキイレ コウ ノ エンドミル カコウ ニ カンスル ケンキュウ ダイ3ポウ ボールエンドミル ノ セッサク テイコウ ノ カンイ スイテイシキ ト ソレニ ヨル セッサク テイコウ ノ イッテイカ セイギョ
  • A Prediction Model of Cutting Forces for Ball End Mills and Control for Constant Cutting Forces Using this Model
  • ボールエンドミルの切削抵抗の簡易推定式とそれによる切削抵抗の一定化制御

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Abstract

This paper deals with the mathematical model for cutting forces by (Al, Ti)N-coated micro-grain carbide ball end mill cutters during end milling of hardened steel for dies and molds. Since it is known that cutting characteristics changes depending upon the location of cutting edge and its chip thickness in ball end milling, a quadratic polynomial model is proposed for the prediction of cutting forces based on the response surface methodology. The model contains three variables of the engagement length of cutting tool, the maximum undeformed chip thickness and the nose engagement angle. The obtained prediction model is shown to be applicable for this problem. In end milling of hardened steel, the control of cutting forces is especially important because chipping occurs easily if the cutting edge is subject to severe cutting force. Furthermore, constant cutting force is required for improving the accuracy of machined surfaces. The prediction and control of cutting forces in pick feed ball end milling which includes both straight and concave contour cutting is very effective using this model.

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