Abstract
The orientation of the tool axis and the variable curvature of the machined profile of a sculptured surface have a significant impact on the roughness and topography of the surface in the process of 5-axis milling by means of a toroidal milling cutter. The selection of the orientation of the toroidal milling cutter axis relative to the radius of curvature of the machined surface profile is very important as it can provide a better surface quality and an even distribution of roughness parameters. In this paper, an attempt to carry out model tests to obtain mathematical relationships was made. These relationships were to determine the impact of the tool axis orientation and the variable curvature radius of the machined profile on the surface roughness and its topography in the 5-axis milling process of sculptured surfaces. The tests were conducted on an example of a turbine blade made of Inconel 718 alloy. A measurable effect of the work undertaken was the development of model relationships that can be applied in specialized modules of CAM (Computer Aided Manufacturing) systems supporting the programming of 5-axis machining of sculptured surfaces. The models developed will also make it possible to obtain an evenly distributed roughness on the machined sculptured surface, especially on the surface of the turbine blades of the Inconel 718 alloy, as indicated by the results of the tests carried out.
Highlights
Sculptured surfaces are currently widely used for the design of complex elements, mainly turbine blades, especially in the aviation and energy industries
Ko et al [9] focused on the lead and tilt angle and cutter path by considering, among others, the surface roughness in their research where the results indicated that a 15◦ inclination angle was optimal
In the case of the radii of the curvature of sculptured surfaces, which are used for profiling turbine blades, Cao et al [4] investigated the effect of the curvature radius of the sculptured surface on finish milling tool path selection, and Yao et al [5] and Yang et al [19] studied the effects of tool orientation and surface curvature on surface integrity in ball end milling
Summary
Sculptured surfaces are currently widely used for the design of complex elements, mainly turbine blades, especially in the aviation and energy industries The surfaces in these types of elements are characterized by a variable radius of a curved line contour along the machined profile. In [1], the authors stated that the machined surface quality resulted from the choice of the strategy and the corresponding cutting parameters According to this statement, they developed a predicting model of the surface roughness of the sculptured surface after 5-axis milling. When analyzing the results obtained by them, it can be stated that the roughness of the curvilinear surface after 5-axis milling was characterized by an uneven distribution of roughness parameters This may be due to the variable curvature radius along the surface profile being machined.
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