Process modeling and toolpath optimization for five-axis ball-end milling based on tool motion analysis
Process modeling and toolpath optimization for five-axis ball-end milling based on tool motion analysis
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DOI：
10.1007/s00170-011-3354-y
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发表时间：
2011-05
期刊：
影响因子：
--
通讯作者：
Liqiang Zhang
中科院分区：
文献类型：
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作者：
Liqiang Zhang
在自由曲面加工中，由于难以确定欠成形切屑厚度和啮合切削刃，五轴球端铣削力的预测是一个相当大的挑战。在高切削力作用下，零件和刀具的偏转可能导致零件质量差。针对这些问题，提出了基于刀具运动分析的五轴铣削加工过程建模与优化方法。几何库存建模选择的方法是dexel方法，提取的刀具工件啮合用作力预测的输入。求出刀具进出角和切削深度，并以此计算瞬时切削力。根据刀具与工件的啮合轨迹变化，通过改变进给来优化加工过程，统一模型为分析五轴铣削提供了有力的工具。新的进给速度曲线在避免加工故障的同时大大缩短了加工时间。
In free-form surface machining, the prediction of five-axis ball-end milling forces is quite a challenge due to difficulties of determining the underformed chip thickness and engaged cutting edge. Part and tool deflections under high cutting forces may result in poor part quality. To solve these concerns, this paper presents process modeling and optimization method for five-axis milling based on tool motion analysis. The method selected for geometric stock modeling is the dexel approach, and the extracted cutter workpiece engagements are used as input to a force prediction. The cutter entry–exit angles and depth of cuts are found and used to calculate the instantaneous cutting forces. The process is optimized by varying the feed as the tool–workpiece engagements vary along the toolpath, and the unified model provides a powerful tool for analyzing five-axis milling. The new feedrate profiles are shown to considerably reduce the machining time while avoiding process faults.