Adaptive method of 5-axis milling of sculptured surfaces elements with a curved line contour

Abstract

In this paper, an attempt to develop a new adaptive method of controlling the axis orientation of a toroidal milling cutter (leading angle α) depending on the radius of curvature (radius ρ1 in the feed direction, i.e. on a curved contour) of the treated surface profile in a 5-axis milling process was made. An application of this method required the development, based on the results of simulation and experimental tests (own tests), of a special procedure for selection of the lead angle α of the milling cutter depending on the continuously changing radius of curvature ρ1 in the direction of the milling cutter. This procedure was implemented in a commercial CAM system, thus modifying the classical strategy of controlling the movement of the tool into an adaptive strategy. The proposed method after entering the criterion of the permissible value of the deviation of shape Δk and limiting the permissible parameter Ra of the surface roughness, allows adapting the lead angle α of the toroidal axis to the current value of the radius of curvature ρ1 of the processed composite surface profile. By conducting experimental research on the example of the blade machining of the turbine blade, it was shown that the concept of a new method of controlling the axis of the toroidal milling axis allows the parameters of the lead angle and radius of curvature (α, ρ1) to increase the accuracy of the 5-axis surface treatment of complex elements with contours curvilinear by about 25 %.