A Study On Parametric Design And Geometry Parameters Optimization Of Ball-end Cutter

A ball-end cutter is an effective cutting tool for curved surface processing, whichis widely used in aviation, automotive, die and other fields. Domestic and overseasscholars have done a lot of work about the structure design and optimization ofball-end cutters. Many scholars focus on the research of the selection andoptimization of the cutting amount, such as the selections of the speed and feed, etc.But the research on the optimization of geometry angle is relatively few. In fact, thegeometrical parameters of ball-end cutters have great effects on its cutting force andlife of usage. Based on the previous research, the research on the parametric entitymodeling and geometric parameter optimization of the ball-end cutter was carried onin this paper.Firstly, the structures and characteristics of ball-end cutters were introduced inthis paper; the research background and current status of ball-end cutters, such asmathematical modeling, computer aided design technology as well as milling forcemodeling were presented, and related problems summarized and the solution methodsput forward; the softwares for CAD and FEM used in this paper were introduced.Secondly, taking cutting edge, spiral milling cutter groove and flank of theball-end cutter into account, the mathematical models were established; Based onmathematical models, the method to confirm the position of the wheel duringprocessing the ball-end cutter was put forward.Thirdly, the formulation of the spiral groove contact line of the grinding wheeland the ball-end cutter was established; the3D parametric design module of ball-endcutter was established based on the powerful feature modeling function of UGsoftware, established mathematics model as well as parameter design technology.Personalized menus and dialog box of the module were developed with the seconddevelopment module of UG/OPEN.Finally, the orthogonal combined simulation scheme with the design factors ofrake angle, spiral angle and relief angle was designed. The analysis of the millingforce produced during cutting stainless steel was carried on with FEM softwareDEFORM. The result was analyzed by the multivariate nonlinear regression techniqueand the milling force regression model established. The genetic algorithm wasadopted to caculate the optimal geometrical parameters and the minimum millingforce obtained. The technologies of CAD and FEM have become more and more important forcomplex tool design, which can not only effectively shorten tool design cycle, butalso improve the performance of cutting tools. The method which was illustrated withthe example of ball-end cutters provides some reference and enlightenment to othercomplex tool optimazation design.