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Research Papers

Analytical Modeling and Simulation of the Envelope Surface in Five-Axis Flank Milling With Cutter Runout

[+] Author and Article Information
Yuwen Sun1

Key Laboratory for Precision and Non-Traditional Machining Technology of the Ministry of Education,  Dalian University of Technology, Dalian, 116024, Chinaxiands@dlut.edu.cn

Qiang Guo

Key Laboratory for Precision and Non-Traditional Machining Technology of the Ministry of Education,  Dalian University of Technology, Dalian, 116024, China116741790@163.com

1

Corresponding author.

J. Manuf. Sci. Eng 134(2), 021010 (Apr 04, 2012) (11 pages) doi:10.1115/1.4005802 History: Received March 19, 2011; Revised November 17, 2011; Published March 30, 2012; Online April 04, 2012

The cutter runout effect has significant influence on the shape of the cutter swept surface and the machining surface quality. Due to the existence of cutter runout effect, the shape and position of envelope surface formed by each cutter edge are different from others. Hence, it is necessary to integrate the cutter runout effect and its resulting compound effects of all cutter edges into envelope surface modeling and form error prediction for five-axis milling. This paper establishes the envelope surface model considering cutter runout effect in five-axis flank milling based on the relative motion analysis of the cutter and part. In this model, the cutter runout is defined by three parameters, including inclination angle, location angle, and offset value, and the cutter runout effect is subsequently integrated into the model by using the cutter edge as the generatrix of cutter rotation surface. Then, the influence of each runout parameter on the shape of envelope surface formed by each cutter edge as well as the resulting form error in milling is investigated. Also, the compound effects of all cutter edges on the final resulting geometric errors of the machined surface are analyzed. Finally, simulations and machining experiment are conducted for a specific ruled surface, and the results validate the effectiveness and feasibility of proposed envelope surface model considering cutter runout effect. It is suitable to be used in tool positioning, tool installation adjustment, and forming error prediction in flank milling process with cutter runout.

Copyright © 2012 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Runout parameters definition

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Figure 14

The relationship between ρ and error values at the different height along the cutter axis

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Figure 15

The error values with different location angles

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Figure 16

The relationship between location angle and error values at different height along cutter axis

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Figure 17

Error values associated with the number of cutter edge

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Figure 18

Error values associated with each cutter edge

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Figure 19

Error surface consider synergistic effects

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Figure 2

Coordinate systems with cutter runout effect

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Figure 3

Transformation from O c to O r

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Figure 4

The rotation surface (a) without cutter runout and (b) with cutter runout

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Figure 5

The rotation surface with multicutter edges

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Figure 6

Point on envelope surface as well as rotation surface

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Figure 7

Envelope surface under existing cutter runout

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Figure 8

The machined workpiece

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Figure 9

Simulation of envelope surface without cutter runout

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Figure 10

Error surface when deflection error is 0.02 rad

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Figure 11

Error comparison for different parameter in Table 1 at the position of 50 mm along length direction

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Figure 12

The relationship between δ and error values at the different height along the cutter axis

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Figure 13

The error surface when ρ = 0.1 mm

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