Authors: Xuewei Zhang Tianbiao Yu Wanshan Wang
Publish Date: 2014/07/06
Volume: 74, Issue: 9-12, Pages: 1611-1624
Abstract
The fiveaxis milling is widely applied to complex surface machining When cutting forces of milling processes increase the consequent workpiece and tool deflections may result in poor machining quality and high processing cost There are a lot of researches on threeaxis milling processes simulation but very few about fiveaxis milling To solve these disadvantages this paper presents an integrated system containing modeling simulation and optimization of fiveaxis milling processes The system has three major applications 1 simulation verification of milling processes 2 cutting forces prediction and 3 cutting parameters feedrate optimization The material removal process simulation used for verifying the fiveaxis milling is based on the threedexel depth element model and the cutterworkpiece engagement regions are extracted from the geometric model According to the extracted cutterworkpiece engagement regions the instantaneous cutting forces could be predicted The feedrate is offline modified for balancing the given maximum or the reference cutting forces with the predicted cutting forces on different machining steps The developed system is validated experimentally to show that the modeling simulation and optimization methods could improve the accuracy and efficiency of fiveaxis milling processes
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