Research Papers

Modeling and Analysis of Five-Axis Milling Configurations and Titanium Alloy Surface Topography

[+] Author and Article Information
David Prat

Arts et Metiers ParisTech,
Rue Porte de Paris,
Cluny 71250, France
e-mail: david.prat@ensam.eu

Guillaume Fromentin

Arts et Metiers ParisTech,
Rue Porte de Paris,
Cluny 71250, France
e-mail: guillaume.fromentin@ensam.eu

Gérard Poulachon

Arts et Metiers ParisTech,
Rue Porte de Paris,
Cluny 71250, France
e-mail: gerard.poulachon@ensam.eu

Emmanuel Duc

Institut Pascal,
Campus des Cézeaux BP265,
Aubière Cedex 63175, France
e-mail: emmanuel.duc@ifma.fr

1Corresponding author.

Manuscript received June 4, 2015; final manuscript received November 13, 2015; published online January 6, 2016. Assoc. Editor: Y. B. Guo.

J. Manuf. Sci. Eng 138(6), 061006 (Jan 06, 2016) (9 pages) Paper No: MANU-15-1275; doi: 10.1115/1.4032083 History: Received June 04, 2015; Revised November 13, 2015

Five-axis milling with a ball-end cutter is commonly used to generate a good surface finish on complex parts, such as blades or impellers made of titanium alloy. The five-axis milling cutting process is not straight forward; local cutting conditions depend a lot on the geometrical configuration relating to lead and tilt angles. Furthermore, the surface quality is greatly affected by the cutting conditions that define the milling configuration. This study presents a geometrical model of five-axis milling in order to determine the effective cutting conditions, the milling mode, and the cutter location point. Subsequently, an analysis of surface topography is proposed by using the geometrical model, local criteria, and a principle component analysis of experimental data. The results show the effects of local parameters on the surface roughness, in relation to the lead and tilt angles.

Copyright © 2016 by ASME
Topics: Cutting , Milling
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Fig. 4

Algorithm for the computation of effective cutting radius

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Fig. 3

Machined part with the cut and finished surfaces

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Fig. 2

Definition of the βf lead and βn tilt angles and aa axial and ar radial depth of cut

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Fig. 1

Effective cutting radius on the cut and finished surface (βf=20 deg, βn=0 deg, ar=0.4 mm, and aa=0.3 mm)

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Fig. 8

Surface topography of two different areas of the same surface (βf=45 deg, βn=0 deg, N=3000 rpm, fz=0.12 mm/th rev, ar=0.4 mm, and aa=0.3 mm): (a) area with two paths in opposite phase and (b) area with two paths traces in phase

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Fig. 7

Effective cutting radius and milling modes of four situations (aa = 0.15 mm)

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Fig. 5

Geometry of the ball-end mill cutter used in the study

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Fig. 6

Milling mode for the configuration (βf=20 deg, βn=0 deg, ar=0.4 mm, and aa=0.3 mm)

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Fig. 9

Projection of individuals on the 1st and 2nd factors to study the influence of the milling mode

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Fig. 10

Projection of individuals on the 1st and 2nd factors to study the influence of the cutting speed

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Fig. 11

Representation of configurations to study the influence of the cutter location point position (ar=0.4 mm and aa=0.3 mm)

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Fig. 12

Projection of individuals on the factors 1 and 2 to study the influence of the cutter location point position

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Fig. 13

Transversal profile of configurations 6, 8, and 12




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