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research-article

Stability prediction based effect analysis of tool orientation on machining efficiency for five-axis bull-nose end milling

[+] Author and Article Information
Xiaowei Tang

School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
txwysxf@126.com

Zerun Zhu

School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
eonpig@hust.edu.cn

Rong Yan

School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
yanrong@hust.edu.cn

Chen Chen

School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
chenchen1990@hust.edu.cn

Fang Yu Peng

State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, China
zwm8917@263.net

Mingkai Zhang

School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
zmk0509@163.com

Yuting Li

School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
lytwhut@163.com

1Corresponding author.

ASME doi:10.1115/1.4041426 History: Received May 22, 2018; Revised September 03, 2018

Abstract

The traditional stability analysis with only considering cutting depth-spindle speed lobe diagram is appropriate for parameters optimization and efficiency improvement of the five-axis ball-end milling. However due to the complicated cutter-workpiece engagement (CWE) of bull-nose end cutter in five-axis milling, the maximal cutting depth may not produce the maximal material removal rate (MRR). Thus, the traditional stability analysis is not suit for the five-axis bull-nose end milling in parameters optimization, and this paper presents a new stability analysis method to analyze the effect of tool orientation on machining efficiency for five-axis bull-nose end milling. In the establishing of stability prediction model, coordinate transformation and vector projection method are adopted to identify the CWE and dynamic cutting thickness, and the geometrical relationship of frequency response function (FRF) coordinate system and cutting force coordinate system with variable tool orientation is derived to establish the conversion of FRF and cutting force in stability equation. Based on the CWE sweeping, the cutting area along the feed direction is calculated to realize the critical MRR analysis in the stability model. Based on the established stability prediction model, the effects of tool orientation on critical cutting depth and MRR considering the chatter constraint are analyzed and validated by the cutting experiments respectively. The lead-tilt diagram with not only giving the boundary of stability region but also describing the contour line for MRR is proposed for the further tool orientation optimization.

Copyright (c) 2018 by ASME
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