Research on surface morphology of the ruled surface in five-axis flank milling

Abstract

Due to the complexity of ruled surface blade in five-axis flank milling and the limited interpolation capacity of Computer Numerical Control system, the continuous tool location trajectory can only be approximated as a combination of a series of micro linear segments in flank milling process. As a result, the smooth ruled surface is decomposed into many micro planes. In this paper, the generation principle of surface morphology for the micro plane is studied without considering the tool vibration, the workpiece vibration, and shape and position errors of the tool in the milling. In the surface morphology simulation of each micro plane, a fixed plane I which is stationary and perpendicular to the micro plane is firstly defined, then the intersection distribution between each cutter tooth and the fixed plane I is studied when the cutter has no speed in the direction that is vertical to the tool axis, and then the intersection distribution can turn to the groove lines of surface morphology when the speed vertical to the cutter axis exists. For the other part of morphology besides groove lines, tool’s trochoid motion along the workpiece is approximated as arc motion, so the ridges and grooves are taken shape combined with the entry angle and the exit angle of the tool. The simulation result proves the correctness of the model.