The prediction of chatter vibrations between the cutter and workpiece is important as a guidance to the machine tool user for an optimal selection of depth of cut and spindle rotation, resulting in maximum chip removal rate without this undesirable vibration. This can be done by some approaches. In this work, an analytical method is applied in which the time-varying directional dynamic milling ...

With the rapid development of high-precision-device technology, new demands are put forward for micro milling. The size effect and low cutting energy milling make process expensive difficult, especially Ti-6Al-4V alloys. wear micro-milling cutter lacks corresponding international standards its mechanism is complex. In this paper, four kinds cutters with different states were obtained by designi...

A new digital-based model is presented for the prediction cutting forces in 3-axis CNC milling of surfaces. The model uses an algorithm to detect the work-piece/cutter intersection domain automatically for given cutter location (CL), cutter and work-piece geometries. The algorithm uses a voxelization framework to voxelize the cutter helix as well as the work-piece and based on voxel intersectio...

Presented in this paper is a new approach to 5-axis CNC tool path generation for sculptured surface machining with a flat-end cutter. Rational Bézier and B-spline motions are used to plan cutter motions so that an exact representation of the effective cutting shape can be obtained. The exact representation leads to an accurate computation of the scallop curve generated by two adjacent tool path...

This paper proposes a novel method for generation of optimized tool path in 5-axis flank milling of ruled surfaces based on Particle Swarm Optimization (PSO). The 3D geometric problem, tool path generation, is transformed into a mathematical programming task with the machined surface error as the objective function in the optimization. This approach overcomes the limitation of greedy planning m...

Face milling is an important and common machining operation because of its versatility and capability to produce various surfaces. Face milling is a machining process of removing material by the relative motion between a work piece and rotating cutter with multiple cutting edges. It is an interrupted cutting operation in which the teeth of the milling cutter enter and exit the work piece during...

Purpose: This paper presented a method for generating the toolpaths for the machining of a helical rotor on five-axis machine tool. Design/methodology/approach: The geometry of the helical rotor is designed based on the ruled surfaces. Through the homogeneous coordinate transformation, the cutter location of the flank milling for four-axis machining can be generated. The postprocessor are devel...

This paper focuses on the mathematical modeling for 5-axis milling with a filleted end mill. Several coordinate systems are introduced to describe the relationship between a cutter orientation and a machined surface. Then, a cutting point on a cutting edge is geometrically formulated as an integrated form of some expressions. The fundamental simulations based on the modeling were implemented to...

This paper presents an improved tool positioning strategy in the 5-axis flank milling of a ruled surface by using simultaneous perturbation stochastic approximation (SPSA) techniques. The SPSA allows the near-global optimization of the machining error, even though the corresponding objective is not formulated as a closed-form representation. It adjusts all cutter locations of a tool path simult...