Abstract
With the increasing demand for higher quality and performance of equipment and assembly in aerospace, shipbuilding, medical and other fields, the machining accuracy of parts is facing higher requirements. It is particularly important to predict the cutting force accurately, which is the main physical quantity in the machining process and basis of process inspection and quality control. In this paper, the cutting force model in five-axis milling with fillet-end cutter is proposed, which reveals the law of force–deflection coupling. Firstly, the initial cutter deflection model induced by the ideal cutting force ignoring the effect of deflection is built based on analysis of the geometric characteristics of fillet-end cutter. Then, the undeformed chip thickness model is educed considering the cutter posture and cutter deflection. Further, the iterative method is utilized to resolve the coupling relationship between cutter deflection and cutting force. Finally, the cutting force model under force–deflection coupling is established for achieving more accurate prediction. To verify the effectiveness of the proposed cutting force model, the milling experiment is carried out on a five-axis milling center. The measured cutting force values are utilized to inspect the accuracy of prediction models considering and not considering force–deflection coupling, respectively. The results show that the proposed method could improve the prediction accuracy of cutting force, which show the effectiveness of taking force–deflection coupling law into consideration clearly. The influence of cutter posture on cutting force is analyzed using the proposed cutting force model. The cutting force decreases with the increase in lead angle or tilt angle, and the influence of tilt angle is greater than that of lead angle under experimental conditions of five-axis milling using the set process parameters.
Highlights
With the rapid development of the industry such as aerospace, shipbuilding equipment medical, etc., the requirements of equipment service performance are improved, which puts forward an urgent demand for the machining accuracy of key parts
This paper proposed the undeformed chip thickness model considering the cutter posture and cutter deflection by analyzing the interaction between force and deflection based on the established geometric model of the fillet-end cutter according to the geometric characteristics
The calculation method of cutting force prediction based on analysis of relationship between force and deflection for five-axis machining is presented, which contains the influence of cutter posture and cutter deflection for more accurately prediction of the cutting force
Summary
With the rapid development of the industry such as aerospace, shipbuilding equipment medical, etc., the requirements of equipment service performance are improved, which puts forward an urgent demand for the machining accuracy of key parts. These parts usually have complex free-form surface with characteristics of nonlinear contour, large surface curvature changes and overlapping machining features. The taking of deflection into account makes the accurate prediction of cutting force becomes much more difficult because the cutter-workpiece engagement becomes more complex. The free-form surface of the part makes the cutter posture change in five axis machining, so the lead angle and tilt angle should be considered in the cutting force model. Based on the classical cutting force theory of predecessors, there has been a significant development in the cutting force model
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