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

Abstract

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.

A discrete simulation-based algorithm for the technological investigation of 2.5D milling operations

“…In light of the above, it can be concluded that the analytical methods can be applied to simple tool paths, 24 but in the case of modern tool paths, which consist of freeform curves, geometric simulation cannot be neglected or replaced by other simulation methods in machining process analysis. 25 This is because the interaction of the tool and the workpiece depends on in-process geometry, which is a function of former tool path segments.…”