Extraction of 5-axis milling conditions from CAM data for process simulation

Tunç, Taner L. and Budak, Erhan (2009) Extraction of 5-axis milling conditions from CAM data for process simulation. International Journal of Advanced Manufacturing Technology, 43 (5-6). pp. 538-550. ISSN 0268-3768 (Print) 1433-3015 (Online)

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5-axis milling is widely used in machining of parts with free-form surfaces and complex geometries. Although in general 5-axis milling increases the process capability, it also brings additional challenges due to complex process geometry and mechanics. In milling, cutting forces, tool deflections, and chatter vibrations may reduce part quality and productivity. By use of process simulations, the undesired results can be identified and overcome, and part quality and productivity can be increased. However, machining conditions and geometry, especially the tool-work engagement limits, are needed in process models which are used in these simulations. Due to the complexity of the process geometry and continuous variation of tool-work engagement, this information is not readily available for a complete 5-axis milling cycle. In this study, an analytical method is presented for the identification of these parameters from computer-aided manufacturing data. In this procedure, depths of cut, lead, and tilt angles, which determine the tool-workpiece engagement boundaries, are directly obtained the cutter location file analytically in a very fast manner. The proposed simulation approach is demonstrated on machining of parts with relatively complex geometries.
Item Type: Article
Uncontrolled Keywords: 5-axis milling; Sculptured surface; Milling conditions; Airfoil machining
Subjects: T Technology > T Technology (General)
T Technology > TJ Mechanical engineering and machinery
Divisions: Faculty of Engineering and Natural Sciences > Academic programs > Mechatronics
Faculty of Engineering and Natural Sciences > Academic programs > Manufacturing Systems Eng.
Depositing User: Erhan Budak
Date Deposited: 28 Dec 2009 17:02
Last Modified: 26 Apr 2022 08:35
URI: https://research.sabanciuniv.edu/id/eprint/13628

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