Abstract
The paper presents a method of forecasting the product surface topography after five-axis machining with a lens-shaped end-mill. Surface roughness is one of the key parameters considered when assessing the effectiveness of the machining process, especially in the aviation, automotive, tooling and medical equipment industries. The developed method, the first published, presented in the paper is based on the analytical equations of the trajectory of the cutting edge motion, on the basis of which the cutter action surface is generated. The developed model takes into account: cutting depth, cutting width, feed, lead angle and radial runout. Experimental studies were conducted using three different materials: 40HM steel, Al7035 aluminum alloy and Ti Grade 5 titanium alloy. Various values of the cutting width parameters and different feeds were used in the tests. Based on the results of the experimental tests, an empirical model (response surface model) was determined and was then used to verify the simulation model. The simulation results and the results of experimental tests were compared and conclusions were drawn regarding the developed models. The developed models supported by numerical simulation can be used to approximately estimate the influence of the width of cut and feed on selected height characteristics and of the geometric structure of the surface (GSS) after machining with a lens-shaped end-mill in terms of the process parameters adopted in the tests. It was found that the influence of the on the and is greater for small values of . The effect of is greater with lower values. The cutting width has the greatest influence on and , and and the interaction of these parameters has the least influence.
Highlights
The five-axis milling technology is used in the production of parts with very high design requirements [1,2,3]
The observation of the topography maps confirms that the br parameter has a very significant influence on the height parameters of the surface topography
At small values of the cutting width br, the unevenness resulting from the overlapping of the machining paths is so small that the unevenness resulting from the feed movement of the cutting edge is clearly noticeable
Summary
The five-axis milling technology is used in the production of parts with very high design requirements [1,2,3] These requirements include surface roughness, which is of key importance for the durability and reliability of manufactured parts [4,5]. It affects the coefficient of friction [6,7,8], fatigue strength [9,10], wear resistance [11,12,13], corrosion [14,15]. New solutions are still being sought to increase the efficiency of the milling process [3,18,19]
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