Process simulation for 5-axis machining using generalized milling tool geometries

Özkırımlı, Ömer Mehmet and Budak, Erhan (2010) Process simulation for 5-axis machining using generalized milling tool geometries. In: 14. Uluslararası Makina Tasarım ve İmalat Kongresi (UMTİK 2010), Güzelyurt, North Cyprus

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Multi-axis machining (especially 5-axis machining) is widely used in precision machining for automotive, aerospace and die-mold manufacturing. The goal in precision machining is to increase production while meeting high part quality needs which can be achieved through decision of appropriate process parameters considering machine tool constraints (such as power and torque), chatter-free operations and part quality. In order to predict and decide on optimal process parameters, simulation models are used. In the literature, individual tool geometries for multi-axis machining are examined in detailed with different modeling approaches to simulate cutting forces. In this study, a general numerical model for 5-axis machining is proposed covering all possible tool geometries. Tool envelope is extracted from CAD data, and helical flutes points are represented in cylindrical coordinates. Equal parallel slicing method is utilized to find cutter engagement boundaries (CEB) determining cutting region of the tool surface. for each axial level in the tool axis direction. For each level uncut chip thickness value is found and total forces are calculated by summing force values for each point along the cutting flutes. For arbitrary cases forces are simulated and obtained results are experimentally verified.

Item Type:Papers in Conference Proceedings
Uncontrolled Keywords:Multi-axis machining, APT tools, Process simulation, Tool engagement
Subjects:T Technology > TJ Mechanical engineering and machinery
ID Code:15606
Deposited By:Erhan Budak
Deposited On:02 Dec 2010 15:35
Last Modified:29 Jul 2019 12:08

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