Machining deformation prediction of thin-walled workpieces in five-axis flank milling

This paper presents process optimization for the five-axis milling based on the mechanics model explained in Part I. The process is optimized by varying the feed as the tool-workpiece engagements. The linear and angular feedrates are optimized by sequential quadratic programming. Sharp feedrate changes may result in undesired feed-marks on the finished surface. The adopted step is to update the the original CL file with optimized and filtered feedrate commands. The five-axis milling process is simulated in a virtual enviroment, and the resulting feedrate outputs are stored at each position along the tool path. The new feedrate profiles are shown to considerably reduce the machining time while avoiding process faults.

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Compensation of deformation errors in five-axis flank milling of thin-walled parts via tool path optimization

Precision Engineering ◽

10.1016/j.precisioneng.2018.08.010 ◽

2019 ◽

Vol 55 ◽

pp. 77-87 ◽

Cited By ~ 10

Author(s):

Zhou-Long Li ◽

Li-Min Zhu

Keyword(s):

Tool Path ◽

Path Optimization ◽

Flank Milling ◽

Tool Path Optimization ◽

Thin Walled ◽

Five Axis

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Error compensation in the five-axis flank milling of thin-walled workpieces

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405418780163 ◽

2018 ◽

Vol 233 (4) ◽

pp. 1224-1234 ◽

Cited By ~ 4

Author(s):

Hao Si ◽

Liping Wang

Keyword(s):

Cutting Force ◽

Error Compensation ◽

Aviation Industry ◽

Flank Milling ◽

Force Model ◽

Beam Model ◽

Compensation Strategy ◽

Axis Orientation ◽

Thin Walled ◽

Five Axis

Five-axis flank milling is the most commonly used processing method in the aviation industry for the machining of thin-walled parts with complex ruled surfaces. During machining, the tool/workpiece deformations caused by the cutting force often lead to surface errors on the machined components that severely affect the accuracy of the machining results. This article presents an iterative compensation strategy to reduce the tool/workpiece deformation-induced surface error during the five-axis flank milling of thin-walled workpieces by modifying the tool tip position and tool axis orientation. This approach can be implemented in four steps. First, a highly integrated cutter-workpiece engagement extraction method is developed for the construction of a flexible cutting force model that can follow changes in the process geometry. Second, the tool/workpiece deformations are predicted by the cantilever beam model and finite element model, respectively. Third, an off-line error compensation scheme is performed at each cutting location of the tool path to obtain the modified tool position. Fourth, the machined surface of the workpiece model is reconstructed, and the compensated machining code, which can be used directly for actual machining, is generated. A case study is presented at the end of this article, and the effectiveness of the present compensation strategy is verified by machining experiments.

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Surface form error prediction in five-axis flank milling of thin-walled parts

International Journal of Machine Tools and Manufacture ◽

10.1016/j.ijmachtools.2018.01.005 ◽

2018 ◽

Vol 128 ◽

pp. 21-32 ◽

Cited By ~ 40

Author(s):

Zhou-Long Li ◽

Oguzhan Tuysuz ◽

Li-Min Zhu ◽

Yusuf Altintas

Keyword(s):

Flank Milling ◽

Error Prediction ◽

Surface Form ◽

Form Error ◽

Thin Walled ◽

Five Axis

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Research on Five-Axis Dual-NURBS Adaptive Interpolation Algorithm for Flank Milling

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.443.330 ◽

2010 ◽

Vol 443 ◽

pp. 330-335 ◽

Cited By ~ 1

Author(s):

Yu Han Wang ◽

Jing Chun Feng ◽

Sun Chao ◽

Ming Chen

Keyword(s):

Tool Path ◽

Flank Milling ◽

Interpolation Algorithm ◽

Machining Time ◽

Surface Machining ◽

Tool Axis ◽

Scanning Area ◽

Nurbs Interpolation ◽

Milling Method ◽

Five Axis

In order to exploit the advantages of five-axis flank milling method for space free surface machining to the full, a definition of non-equidistant dual-NURBS tool path is presented first. On this basis, the constraint of velocity of points on the tool axis and the constraint of scanning area of the tool axis are deduced. Considering both of these constraints, an adaptive feed five-axis dual-NURBS interpolation algorithm is proposed. The simulation results show that the feedrate with the proposed algorithm satisfies both of the constraints and the machining time is reduced by 38.3% in comparison with the constant feed interpolator algorithm.

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