Cutting edge element modeling-based cutter-workpiece engagement determination and cutting force prediction in five-axis milling

Abstract

Five-axis milling has becoming more popular and widely used in various fields recently, such as aerospace, aviation, shipbuilding, and so on, owing to its capacity to realize higher precision and efficiency. However, the cutter-workpiece engagement (CWE) determination and cutting force prediction in five-axis milling become complicated and remain a challenge by reason of the engagement geometric complexity. This paper presents a CWE determination method based on cutting edge element modeling in five-axis filleted end milling. In the method, the undeformed chip thickness is deduced by exact analysis of translation and rotation of the cutting edge element, and the CWE determination is performed using designed method based on cutting edge elements classification. Then the cutting force model is built using proposed cutting edge element model and CWE determination method. Five-axis machining validation experiments are conducted in a milling center. The results show the effectiveness of the model and support the analysis of influence rule of cutter attitude angle on cutting force.