Abstract
This contribution deals with the accuracy of machining during free-form surface milling using various technologies. The contribution analyzes the accuracy and surface roughness of machined experimental samples using 3-axis, 3 + 2-axis, and 5-axis milling. Experimentation is focusing on the tool axis inclination angle—it is the position of the tool axis relative to the workpiece. When comparing machining accuracy during 3-axis, 3 + 2-axis, and 5-axis milling the highest accuracy (deviation ranging from 0 to 17 μm) was achieved with 5-axis simultaneous milling (inclination angles βf = 10 to 15°, βn = 10 to 15°). This contribution is also enriched by comparing a CAD (Computer Aided Design) model with the prediction of milled surface errors in the CAM (Computer Aided Manufacturing) system. This allows us to determine the size of the deviations of the calculated surfaces before the machining process. This prediction is analyzed with real measured deviations on a shaped surface—using optical three-dimensional microscope Alicona Infinite Focus G5.
Highlights
There is a schematic diagram of the aspects that should be monitored when comparing the machining process during 3-axis and multiaxis milling.The tool axis inclination against a workpiece has a significant influence on the size and direction of the cutting forces [1,2]
The results show the quality of the computational algorithm used in the CAM module of 5-axis milling
It can be concluded that the tool inclination has an influence on the accuracy of machining after the final experiment evaluation
Summary
The radial, axial, and tangential cutting forces tend to push the tool apart It is, appropriate to verify to what extent the proposed changes in the tool axis inclination angle affect the accuracy of the machined surface. Studies on machined surface topography while changing the orientations of the tool axis can be found in the literature [8,9,10,11,12,13,14]. It is important to note that a cycle was used (in the Heidenhain control system) with a tolerance 0.01 mm, which affects the machining accuracy, surface roughness, and feed rate. It is suitable to use CYCL DEF 32.0 TOLERANCE during 5-axis simultaneous machining, including a tolerance for rotary axes TA. The position of the rotary axis to the workpiece surface is changed (ranging 1°)
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