Year: 2025
Type: article
Abstract: Ball-end milling cutters are normally used for complex surface machining. During the milling process, the tool posture and cutting parameters of the ball-end milling cutters have a significant impact on chip formations and morphological changes. Based on the Cutter Workpiece Engagement (CWE) model, this study establishes a chip flow model for ball-end milling cutters with consideration of the tool posture variation. The machining experiments of Ti-6Al-4V with a 15° inclined plane and different feed directions were carried out. The influence mechanism of time-varying tool posture on chip formation was systematically investigated. The results reveal an interaction between the chip flow direction and the cutting velocity direction. The included angle between the chip flow directions at the maximum and minimum contact points in the CWE area affects the degree of chip curling, with a smaller angle leading to weaker curling. This research provides a theoretical foundation for the optimization of posture parameters of ball-end milling cutters and expounds on the influence of the chip flow angle on chip deformation.
Source: Coatings
Authors: Shiqiang Zhou, Anshan Zhang, Xiaosong Zhang, Maiqi Han, Bowen Liu
Institution: Harbin University of Science and Technology
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $3,137
Awards: G1742445288, G5057193468
OpenAlex ID: W4413059498