Process simulation for five-axis machining for generalised milling tools

Official URL: http://dx.doi.org/10.1504/IJDE.2010.039758

In this study, a general numerical model for five-axis machining is proposed covering all possible tool geometries. The proposed process model predicts total cutting forces acting on the tool given the cutter profile geometry, process conditions and material specifications without preliminary cutting operations. Tool envelope is extracted from CAD data, and helical flutes points are represented in cylindrical coordinates. Equal parallel slicing method is utilised 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.