Using the direct cutting paths approach on aluminum alloy cone frustum part for evaluating a five-axis machine tool with Taguchi method

Abstract

It is difficult to compare five-axis machine tools complex analysis against independent motion of multi-type machines; more specifically, there has been no breakthrough involving the interaction effect factors from cutting analysis. Therefore, the defining and quantifying of data are important in assessing the overall performance of five-axis machine tools, and allow for the evaluation of each subsequent interaction motion analysis. Among various cutting test models, the machining of a cone frustum as specified in National Aerospace Standard 979 and International Standard Organization 10791-7 is widely accepted as a performance test standard for five-axis machining centers. Although it gives a demonstration of the machine’s machining performance, it is generally difficult to identify the overall effects of kinematic interaction within the profile of the finished workpiece. This is new approach to a previously defined 10 direct cutting paths method to evaluate the performance of each cone frustum motion, and it is not limited to only evaluating single direction or displacement on a five-axis machine tool. Among the 10 cutting paths, four of them are real five-axis cutting and the remaining paths are non-real five-axis cutting. This allowed the test of four to five mixed external forces at the same time, which the instrument is not able to measure. This article further proposes to calculate the factorial effect of interaction, based on the Taguchi method signal-to-noise ratio, mechanical advantage, and Variables separable model, which allows for the comparison of the performance of different five-axis machine tool types.