Determination of the feasible setup parameters of a workpiece to maximize the utilization of a five-axis milling machine

Abstract

The machining industry must maximize the machine tool utilization for its efficient and effective usage. Determining a feasible workpiece location is one of the significant tasks performed in an iterative way via machining simulations. The maximum utilization of five-axis machine tools depends upon the cutting system’s geometry, the configuration of the machine tool, and the workpiece’s location. In this research, a mathematical model has been developed to determine the workpiece’s feasible location in the five-axis machine tool for avoiding the number of iterations, which are usually performed to eliminate the global collision and axis limit errors. In this research, a generic arrangement of the five-axis machine tool has been selected. The mathematical model of postprocessor has been developed by using kinematic modeling methods. The machine tool envelopes have been determined using the post-processor and axial limit. The tooltip reachable workspace is determined by incorporating the post-processor, optimal cutting system length, and machining envelope, thereby further developing an algorithm to determine the feasible workpiece setup parameters accurately. The algorithm’s application has been demonstrated using an example. Finally, the algorithm is validated for feasible workpiece setup parameters in a virtual environment. This research is highly applicable in the industry to eliminate the number of iterations performed for the suitable workpiece setup parameters.