斜面のボールエンドミル加工における工具挙動と仕上げ面生成機構の解析 (第1報) : —工具挙動の解析モデルおよび解析結果と実験結果との比較—

概要

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By using a cutting model and energy method proposed in previous papers, cutting forces in various milling processes in which both cutting edges of spherical and cylindrical portions engage with the workpiece can be predicted, and distribution of cutting forces along the cutting edge also obtained. To clear the behavior of tool deflection and the mechanism of machined surface generation in milling along a contour line of an inclined surface, FEM model of a ball end mill is constructed by using geometrical data of cross section of the tool. The tool deflection and locus of tool axis during milling are analyzed by using the cutting force data predicted and the FEM model of a ball end mill. In the analysis, radial force components distributed along the cutting edge are applied to the FEM model and support condition of the tool is experimentally determined on the basis of a bending test of a cylindrical bar conducted on machine tool. Tool deflection and behavior of the tool axis during contour milling of inclined surfaces is measured by using an eddy-current type sensor and compared with the predicted results. The predicted results are in good agreement with the experimental results. It is shown that the tool deflection and behavior of the tool axis vary considerably with the feed direction of the tool. For milling an inclined surface where the left side of the feed direction is higher, the tool axis deflects to be drawn toward the inclined surface.