Mechanistic Model Based on the Actual Removal Volume during Simultaneous Five-Axis Milling
In this paper we present a novel mechanistic model of cutting process of the cylindrical tool by using the actual removal volume per tooth via NC simulation. The simulation kernel enables “virtually” cutting the workpiece in milling process per NC code, as well as calculating the removal volume per tooth which leads to predict the actual cutting force during simultaneous five-axis machining. Combined with the material removal simulation, the advanced mechanistic process model, which can enable the prediction of the cutting force and adjust the trajectory velocity of the cylindrical tools undergoing five-axis movement, is presented by applying the line integral along the cutting edge and taking the rake angle and cutting edge roundness into consideration. The novel methodology to adjust the cutting force by prevailing cutting tools undergoing multi-axis motion is to be validated by experiment and integrated into tool path planning systems.
S. W. Lee and A. Nestler, "Mechanistic Model Based on the Actual Removal Volume during Simultaneous Five-Axis Milling", Advanced Materials Research, Vol. 223, pp. 713-722, 2011