Abstract
Feed rate assignment in five-axis surface machining is constrained by many factors, among which a particularly critical one is the deflection cutting force on the tool: while a larger feed rate increases the machining productivity by shortening the total machining time, it nevertheless inevitably enlarges the deflection cutting force as well, which will cause the tool to be more prone to bending and the machine more prone to vibration, thus adversely degrading the surface finish quality. In this paper, we present a new five-axis tool path generation algorithm that strives to globally maximize feed rate for an arbitrary free-form surface while respecting a given deflection cutting force threshold. The crux of the algorithm is a new concept of the (cutting) force–area quotient function—at any cutter contact point on the surface, the maximal effective material removal rate (with respect to the deflection cutting force threshold) is a continuous function of the feed direction. This function induces a potential field on the surface and based on which an efficient tool path generation algorithm is designed. Preliminary experiments show that substantial reduction in total machining time can often be achieved by the proposed algorithm.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Lee P, Altintaş Y (1996) Prediction of ball-end milling forces from orthogonal cutting data. Int J Mach Tools Manuf 36:1059–1072
Li Y, Liang SY (1999) Cutting force analysis in transient state milling processes. Int J Adv Manuf Technol 15:785–790
Lee T, Lin Y (2000) A 3D predictive cutting-force model for end milling of parts having sculptured surfaces. Int J Adv Manuf Technol 16:773–783
Engin S, Altintas Y (2001) Mechanics and dynamics of general milling cutters. Part I: helical end mills. Int J Mach Tools Manuf 41:2195–2212
Kim G, Cho P, Chu C (2000) Cutting force prediction of sculptured surface ball-end milling using Z-map. Int J Mach Tools Manuf 40:277–291
Kim GM, Chu CN (2004) Mean cutting force prediction in ball-end milling using force map method. J Mater Process Technol 146:303–310
Zhu R, Kapoor SG, DeVor RE (2001) Mechanistic modeling of the ball end milling process for multi-axis machining of free-form surfaces. J Manuf Sci Eng 123:369–379
Kim Y-H, Ko S-L (2006) Improvement of cutting simulation using the octree method. Int J Adv Manuf Technol 28:1152–1160
Ozturk B, Lazoglu I (2006) Machining of free-form surfaces. Part I: analytical chip load. Int J Mach Tools Manuf 46:728–735
Azeem A, Feng H-Y, Wang L (2004) Simplified and efficient calibration of a mechanistic cutting force model for ball-end milling. Int J Mach Tools Manuf 44:291–298
Lamikiz A, LópezdeLacalle L, Sanchez J, Salgado M (2004) Cutting force estimation in sculptured surface milling. Int J Mach Tools Manuf 44:1511–1526
Ozturk B, Lazoglu I, Erdim H (2006) Machining of free-form surfaces. Part II: calibration and forces. Int J Mach Tools Manuf 46:736–746
Suresh K, Yang D (1994) Constant scallop-height machining of free-form surfaces. J Eng Ind 116:253–259
Lo C-C (1999) Efficient cutter-path planning for five-axis surface machining with a flat-end cutter. Comput Aided Des 31:557–566
Chiou C-J, Lee Y-S (2002) A machining potential field approach to tool path generation for multi-axis sculptured surface machining. Comput Aided Des 34:357–371
Kim T, Sarma SE (2002) Toolpath generation along directions of maximum kinematic performance; a first cut at machine-optimal paths. Comput Aided Des 34:453–468
López de Lacalle L, Lamikiz A, Sanchez J, Salgado M (2007) Toolpath selection based on the minimum deflection cutting forces in the programming of complex surfaces milling. Int J Mach Tools Manuf 47:388–400
Lazoglu I, Manav C, Murtezaoglu Y (2009) Tool path optimization for free form surface machining. CIRP Ann Manuf Technol 58:101–104
Ko T, Kim H, Lee S (2001) Selection of the machining inclination angle in high-speed ball end milling. Int J Adv Manuf Technol 17:163–170
Toh C (2006) Cutter path orientations when high-speed finish milling inclined hardened steel. Int J Adv Manuf Technol 27:473–480
Ozturk E, Tunc LT, Budak E (2009) Investigation of lead and tilt angle effects in 5-axis ball-end milling processes. Int J Mach Tools Manuf 49:1053–1062
Kurt M, Bagci E (2011) Feedrate optimisation/scheduling on sculptured surface machining: a comprehensive review, applications and future directions. Int J Adv Manuf Technol 55:1037–1067
Erdim H, Lazoglu I, Ozturk B (2006) Feedrate scheduling strategies for free-form surfaces. Int J Mach Tools Manuf 46:747–757
Salami R, Sadeghi M, Motakef B (2007) Feed rate optimization for 3-axis ball-end milling of sculptured surfaces. Int J Mach Tools Manuf 47:760–767
Ko JH, Yun WS, Cho D-W (2003) Off-line feed rate scheduling using virtual CNC based on an evaluation of cutting performance. Comput Aided Des 35:383–393
Feng H-Y, Su N (2000) Integrated tool path and feed rate optimization for the finishing machining of 3D plane surfaces. Int J Mach Tools Manuf 40:1557–1572
Budak E, Altintas Y, Armarego E (1996) Prediction of milling force coefficients from orthogonal cutting data. J Eng Ind 118:216–224
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Xu, K., Tang, K. Five-axis tool path and feed rate optimization based on the cutting force–area quotient potential field. Int J Adv Manuf Technol 75, 1661–1679 (2014). https://doi.org/10.1007/s00170-014-6221-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-014-6221-9