Computing of the actual shape of removed material for five-axis flat-end milling

2012 ◽  
Vol 44 (11) ◽  
pp. 1103-1114 ◽  
Author(s):  
Denys Plakhotnik ◽  
Bert Lauwers
Keyword(s):  
End Milling ◽  
Flat End Milling ◽  
Actual Shape ◽  
Five Axis

Prediction of cutting force in five-axis flat-end milling

2018 ◽  
Vol 96 (1-4) ◽  
pp. 137-152 ◽  
Author(s):  
Z. C. Wei ◽  
M. L. Guo ◽  
M. J. Wang ◽  
S. Q. Li ◽  
S. X. Liu
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Flat End Milling ◽  
Five Axis

Prediction and Investigation of Surface Response in High Speed End Milling of Ti-6Al-4V and Optimization by Genetic Algorithm

2009 ◽  
Vol 83-86 ◽  
pp. 1009-1015 ◽  
Author(s):  
S. Alam ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari ◽  
Mohamed Konneh
Keyword(s):  
Experimental Data ◽  
Genetic Algorithm ◽  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Flat End Milling ◽  
Five Axis

In this study, statistical models were developed using the capabilities of Response Surface Methodology (RSM) to predict the surface roughness in high-speed flat end milling of Ti-6Al-4V under dry cutting conditions. Machining was performed on a five-axis NC milling machine with a high speed attachment, using spindle speed, feed rate, and depth of cut as machining variables. The adequacy of the model was tested at 95% confidence interval. Meanwhile, a time trend was observed in residual values between model predictions and experimental data, reflecting little deviations in surface roughness prediction. A very good performance of the RSM model, in terms of agreement with experimental data, was achieved. It is observed that cutting speed has the most significant influence on surface roughness followed by feed and depth of cut. The model can be used for the analysis and prediction of the complex relationship between cutting conditions and the surface roughness in flat end milling of Ti-6Al-4V materials. The developed quadratic prediction model on surface roughness was coupled with the genetic algorithm to optimize the cutting parameters for the minimum surface roughness.

Dynamics and Stability Prediction of Five-Axis Flat-End Milling

2017 ◽  
Vol 139 (6) ◽  
Author(s):  
YaoAn Lu ◽  
Ye Ding ◽  
LiMin Zhu
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Stability Prediction ◽  
Tool Orientation ◽  
Cutting Force Prediction ◽  
Vector Method ◽  
Force Prediction ◽  
Flat End Milling ◽  
The Stability ◽  
Five Axis

The tool orientation of a flat-end cutter, determined by the lead and tilt angles of the cutter, can be optimized to increase the machining strip width. However, few studies focus on the effects of tool orientation on the five-axis milling process stability with flat-end cutters. Stability prediction starts with cutting force prediction, and the cutting force prediction is affected by the cutter-workpiece engagement (CWE). The engagement geometries occur between the flat-end cutter and the in-process workpiece (IPW) are complicated in five-axis milling, making the stability analysis for five-axis flat-end milling difficult. The robust discrete vector method (DVM) is adopted to identify the CWE for flat-end millings, and it can be extended to apply to general cutter millings. The milling system is then modeled as a two-degrees-of-freedom spring-mass-damper system with the predicted cutting forces. Thereafter, a general formulation for the dynamic milling system is developed considering the regenerative effect and the mode coupling effect simultaneously. Finally, an enhanced numerical integration method (NIM) is developed to predict the stability limits in flat-end milling with different tool orientations. Effectiveness of the strategy is validated by conducting experiments on five-axis flat-end milling.

scholarly journals Optimisation of Planning Parameters for Machining Blade Electrode Micro-Fillet with Scallop Height Modelling

Micromachines ◽  
2021 ◽  
Vol 12 (3) ◽  
pp. 237
Author(s):  
Yue Liu ◽  
Zhanqiang Liu ◽  
Wentong Cai ◽  
Yukui Cai ◽  
Bing Wang ◽  
...  
Keyword(s):  
Path Planning ◽  
Tilt Angle ◽  
Tool Path ◽  
End Milling ◽  
Tool Path Planning ◽  
Scallop Height ◽  
Aero Engine ◽  
Tool Tilt Angle ◽  
Five Axis ◽  
Height Model

Aero-engine blades are manufactured by electroforming process with electrodes. The blade electrode is usually machined with five-axis micromilling to get required profile roughness. Tool path planning parameters, such as cutting step and tool tilt angle, have a significant effect on the profile roughness of the micro-fillet of blade electrode. In this paper, the scallop height model of blade electrode micro-fillet processed by ball-end milling cutter was proposed. Effects of cutting step and tool tilt angle the machined micro-fillet profile roughness were predicted with the proposed scallop height model. The cutting step and tool tilt angle were then optimised to ensure the contour precision of the micro-fillet shape requirement. Finally, the tool path planning was generated and the machining strategy was validated through milling experiments. It was also found that the profile roughness was deteriorated due to size effect when the cutting step decreased to a certain value.

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