Analytical methods for increased productivity in 5-axis ball-end milling

Abstract

Five-axis ball-end milling is a technology that many industries such as aerospace, automotive and die/mold employ for complex surface machining. Cutting forces, form errors and chatter vibrations are among the most important limitations in five-axis ball-end milling. Since they are generally not calculated beforehand, machining a product with five-axis ball-end milling may involve iterations on the machine tool due to process problems. In order to eliminate this, process models can be used. An analytical methodology is presented in this paper for modelling of five-axis ball-end milling. The method includes process models, and an interface between process models and CAM software. Process models for cutting force, form error and chatter stability predictions are used in the process planning stage to predict potential problems beforehand, and optimise machining conditions. The process models are presented and verified by experimental tests. The presented method is implemented in a simulation software, and applied in machining of industrial parts where productivity increase for example cases is demonstrated.