Machining strategy development and parameter selection in 5-axis milling based on process simulations

Abstract

In modern machining applications, with the developments in computer-aided manufacturing (CAM) technology, predictive modeling of milling operations has gained momentum. However, there is still a big gap between CAM technology and process modeling which limits its use in machining strategy development and parameter selection. In this paper, an approach is proposed for the use of process models and simulation tools in this direction. Cutting force and stability simulations are used in identification of feasible regions of cutting parameters and comparison of machining strategies for productivity. Cutting force simulation throughout a toolpath is performed through extended Z-mapping approach, where a previously developed generalized cutting force model is utilized. Stability diagrams are generated in frequency domain. Dynamic programming (DP) approach is adapted for machining strategy comparison, which takes into account several constraint curves such as chatter stability, cutting torque, spindle power, tool deflection, and surface roughness. The proposed approach was applied on a case study to demonstrate the use of process models in machining strategy and parameter selection in 5-axis milling.