Feedrate scheduling method for constant peak cutting force in five-axis flank milling process

It is extremely important to select appropriate feedrates for the stable machining of parts with ruled surface in modern aviation industrial applications.However,the current studies take too much time to achieve this goal.Therefore,this paper presents an efficient feedrate optimization method for constant peak cutting force in five-axis flank milling process.The solution method of the instantaneous undeformed chip thickness(IUCT)is proposed using least squares theory with the cutter entry angle and feedrate as variables.Based on this method,an explicit analytical expression of the peak cutting force for each cutting point is established.Furthermore,a feedrate scheduling method is developed to quickly solve the appropriate feedrate under constant peak cutting force.To verify the proposed IUCT model,the fitting IUCT is compared with the accuracy data at different feedrates.Additionally,some experiments of five-axis flank milling are conducted to demonstrate the effectiveness of the peak force model and the feedrate scheduling method.And the surface roughness before and after feedrate scheduling is detected.The results show that the proposed feedrate scheduling method can quickly adjust the feedrate and ensure constant peak force during machining.At the same time,the surface quality is kept at a high level.

Elliptical model for surface topography prediction in five-axis flank milling

In five-axis flank milling operations,the intersecting surfaces of different cutting edges create roughness on the milled surfaces that cannot be ignored in situations with strict requirements,especially in aeronautical manufacturing.To focus on motion problems in milling operations,this paper presents a new model that utilizes elliptical paths as cutting edge trajectories on 3D surface topography machined by peripheral milling.First,the cutter parallel axis offset and location angle are considered,which change the location of the ellipse center and intersection point of the cutting edges.Then,through the proposed model,the predicted surface topography is obtained,and the factors that affect the development tendency of roughness are analyzed.Next,the effects of the cutter location position(CLP)geometric parameters,cutter parallel axis offset and curvature on the roughness are evaluated by a numerical simulation.Finally,machining tests are carried out to validate the model predictions,and the results show that the surface topography predictions correspond well with the experimental results.