The designs of modern vehicles and aviation can be traced to a constant increase in the range of parts that have complexly shaped free-form surfaces. Production of such quality parts requires new methods of automated mechanical engineering and particularly program operated multi-purpose five-coordinate machine processing. The paper is dedicated to dynamical modelling of surface treatment of materials by spherical cylindrical milling cutter. The simulation results are the basis for the formation of optimal conditions for machining free-form surfaces and determining combinations of tilt and advance angles and their optimization for positioning the tool for end milling of surfaces on five-axis CNC machines.
This article presents the results of single-factor modeling and analysis of the influence of tool orientation with regard to the tilt angle and lead angle, on cutting forces when finish milling by a ball end cutter. The program NX 10 is used to build boundaries and contact areas of the tool and the workpiece, and the SIMULIA ABAQUS software is used to create a three-dimensional finite element model and determine the cutting forces. Graphs that describe dependencies of the cutting forces on the tool rotation angle are obtained for different orientations of the tool axis relative to the surface normal. The computational results will allow transition to the two-factor analysis of the influence of tilt angle combinations on the cutting forces and the determination of the optimal tool orientation during five-axis milling with maximum productivity.
The article presents the experimental results of the influences of machining conditions and tool orientation on cutting forces during the end milling of free-form surfaces. A series of experiments are carried out on the machining of steel 3 blanks on a five-axis milling machine model HSC 75 linear using 2-flute and 4-flute ball end mills from MITSUBISHI with diameters from 5 mm to 10 mm. The dependency diagrams and graphs of cutting forces and their projections on cutting time are given at different spindle speeds, feeds per tooth, depths of cut, tilt angles and lead angle when using different ball end mills. Based on the results of the analysis of experimental data, the theoretical conclusion about the increase in cutting forces with increasing feed per tooth, cutting depth and spindle speed in relation to the ball end milling process is confirmed. The critical tool positions with respect to the surface, at which cutting forces have maximum values, are revealed. The obtained results allow developing recommendations for the choice of the tool position during end milling of free-form surfaces to reduce loads on the tool
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