Abstract
Multi-axis milling (especially five-axis) is in the ascendant for high precision manufacturing of a product with a sculptured surface such as ship propeller, owing to its multi-axis linkage and resulting outstanding superiorities. Needs of a faster-improving manufacturing level of sculptured surface milling are derived by higher performance requirement of complicated equipment, which makes the planning of tool orientations more significant and challenging. This paper builds a tool orientation optimization model with inclusion of the influence of deflection error caused by cutting force to achieve better machining precision controlling in five-axis sculptured surface milling. The basic idea of the optimization method is described firstly, followed by the prediction of cutter deflection error. Then determining processes of the related subset to restrain the tool orientations are developed. Lastly, comparative experiments are designed and performed through milling a propeller rotor possessing numerous blades in a five-axis machining center. By comparison with several other tool orientation methods, the average values and volatility of deflection error are both suppressed better utilizing the optimization modeling. The experiment results reflect that it is insufficient to consider single geometric constraint or kinematic constraint, and greater attention should be paid to the role of cutter deflection caused by cutting force in planning the tool orientations.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Fan J, Ball A (2014) Flat-end cutter orientation on a quadric in five-axis machining. Comput Aided Des 53(5):126–138
Kim YJ, Elber G, Bartoň M, Pottmann H (2015) Precise gouging-free tool orientations for 5-axis CNC machining. Comput Aided Des 58(C):220–229
Li X, Lee CH, Hu P, Zhang Y, Yang F (2018) Cutter partition-based tool orientation optimization for gouge avoidance in five-axis machining. Int J Adv Manuf Technol 95(5–8):2041–2057
Zhu Y, Chen ZT, Ning T, Xu RF (2016) Tool orientation optimization for 3+2 -axis cnc machining of sculptured surface. Comput Aided Des 77(C):60–72
Chen ZT, Li SS, Gan ZW, Zhu Y (2017) A highly efficient and convergent optimization method for multipoint tool orientation in five-axis machining. Int J Adv Manuf Technol 93(5–8):2711–2722
Wu B, Liang M, Zhang Y, Luo M, Tang K (2018) Optimization of machining strip width using effective cutting shape of flat-end cutter for five-axis free-form surface machining. Int J Adv Manuf Technol 94(5–8):2623–2633
Gan ZW, Chen ZT, Zhou M, Yang J, Li SS (2016) Optimal cutter orientation for five-axis machining based on mechanical equilibrium theory. Int J Adv Manuf Technol 84(5–8):989–999
Bi QZ, Wang YH, Zhu LM, Ding H (2010) Wholly smoothing cutter orientations for five-axis NC machining based on cutter contact point mesh. Sci China Technol Sci 53:1294–1303
Sun YW, Xu JT, Jin CN, Guo DM (2016) Smooth tool path generation for 5-axis machining of triangular mesh surface with nonzero genus. Comput Aided Des 79(C):60–74
Sun SX, Sun YW, Xu JT, Lee YS (2018) Iso-planar feed vector-fields-based streamline tool path generation for five-axis compound surface machining with torus-end cutters. ASME J Manuf Sci Eng 140(7):071013
Mi Z, Yuan CM, Ma X, Shen LY (2017) Tool orientation optimization for 5-axis machining with c-space method. Int J Adv Manuf Technol 88(5–8):1243–1255
Geng L, Liu PL, Liu K (2015) Optimization of cutter posture based on cutting force prediction for five-axis machining with ball-end cutters. Int J Adv Manuf Technol 78(5):1289–1303
Sung AN, Ratnam MM, Loh WP (2014) Effect of wedge angle on surface roughness in finish turning: analytical and experimental study. Int J Adv Manuf Technol 74:139–150
Campatelli G, Scippa A, Lorenzini L (2014) Workpiece orientation and tooling selection to reduce the environmental impact of milling operations. Procedia Cirp 14(14):575–580
Fard MJB, Bordatchev EV (2013) Experimental study of the effect of tool orientation in five-axis micro-milling of brass using ball-end mills. Int J Adv Manuf Technol 67:1079–1089
Zahrani EG, Sedghi A (2014) Experimental investigation of precision turning of Monel K-500 under dry conditions. Int J Adv Manuf Technol 73:1265–1272
Rodríguez P, Labarga JE (2015) Tool deflection model for micromilling processes. Int J Adv Manuf Technol 76(1–4):199–207
Peng FY, Ma JY, Wang W, Duan XY (2013) Total differential methods based universal post processing algorithm considering geometric error for multi-axis NC machine tool. Int J Mach Tools Manuf 70(70):53–62
Duan XY, Peng FY, Yan R, Zhu ZR, Li B (2015) Experimental study of the effect of tool orientation on cutter deflection in five-axis filleted end dry milling of ultrahigh-strength steel. Int J Adv Manuf Technol 81(1–4):653–666
Zhu ZR, Yan R, Peng FY, Duan XY, Zhou L, Song K (2016) Parametric chip thickness model based cutting forces estimation considering cutter runout of five-axis general end milling. Int J Mach Tools Manuf 101:35–51
Duan XY, Peng FY, Yan R, Zhu ZR, Huang K, Li B (2016) Estimation of cutter deflection based on study of cutting force and static flexibility. J Manuf Sci E-T ASME 138(4):041001–041015
Duan XY, Peng FY, Zhu KP, Jiang GZ (2019) Cutting edge element modeling-based cutter workpiece engagement determination and cutting force prediction in five-axis milling. Int J Adv Manuf Technol, 3
Funding
This work was supported by National Natural Science Foundation of China under Grant No. 51605346 and China Postdoctoral Science Foundation under Grant No. 2016M602374.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Duan, X., Peng, F., Zhu, K. et al. Tool orientation optimization considering cutter deflection error caused by cutting force for multi-axis sculptured surface milling. Int J Adv Manuf Technol 103, 1925–1934 (2019). https://doi.org/10.1007/s00170-019-03663-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-019-03663-9