Abstract
The machining of free-formed surfaces, e.g., dies or moulds, is often affected by tool vibrations, which can affect the quality of the workpiece surface. Furthermore, in 5-axis milling, the dynamic properties of the system consisting of the tool, spindle and machine tool can vary depending on the tool pose. In this paper, a simulation-based methodology for optimising the tool orientation, i.e., tilt and lead angle of simultaneous 5-axis milling processes, is presented. For this purpose, a path finding algorithm was used to identify process configurations, that minimise tool vibrations based on pre-calculated simulation results, which were organised using graph theory. In addition, the acceleration behaviour of the feed drives, which limits the ability of adjusting the tool orientation with a high adaption frequency, as well as potential collisions of the tool, tool chuck and spindle with the workpiece were considered during the optimisation procedure.
Highlights
The machining of free-form surfaces is used, e.g., in the manufacturing of dies and moulds or the production of forming tools for lightweight components
The main criterion of the process stability for discrete positions along the numerically controlled (NC) path, as well as the two constraints of the reachability of the desired axis position and the collision-free swivelling into the corresponding position, were taken into account
An experimentable digital twin of an exemplary machining centre consisting of an axis position-dependent compliance model based on empirical data and kinematic and dynamic models was integrated in a geometric physically-based process simulation system
Summary
The machining of free-form surfaces is used, e.g., in the manufacturing of dies and moulds or the production of forming tools for lightweight components. The tool path in 5-axis milling was optimised based on analytic stability calculation with regard to the engagement situation and process forces, without taking into account the pose-dependent dynamic properties of the system [12]. A method for the optimisation of the dynamic behaviour of the tool by changing the tool orientation along an NC path is presented For this purpose, a geometric physically-based simulation system was used to identify tool poses leading to stable or unstable process behaviour. A geometric physically-based simulation system was used to identify tool poses leading to stable or unstable process behaviour This incorporated the axis position-dependent dynamic properties by means of previously presented models [15,16].
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