Tool Inclination Angle Change Rate Control in Five-Axis Flat-End Milling

Abstract:

Five-axis milling is used in the machining of complex shaped surfaces in a wide range of industries. In five-axis milling, one can adjust inclination angle to adapt such machining condition, e.g. to give high material removal and/or to avoid gouging. Choosing an appropriate inclination angle is difficult especially for complex parts with varying surface curvature. On the one hand, a small inclination angle is recommended to have good surface roughness and small scallop height. On the other hand, some regions may need much larger minimum inclination angle compared to the others to avoid gouging. The trade off for this is to have, in practice, a varying minimum (which is considered to be optimal) inclination angle along the tool path, so that while machining, the tool is dynamically adapted to be as close as possible to the surface without gouging. However, applying inclination angle change over some distances influences the quality of machined surface. This paper presented a method to control such inclination angle change to improve part accuracy. Some experimental were conducted to see the results and compared with the one when inclination angle change is not controled. The propose method effectively reduces the surface deviation thus improve part accuracy. More details about this study are presented in the paper.

• Periodical: Advanced Materials Research (Volumes 488-489)
• Pages: 819-825
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.488-489.819
• Online since: March 2012
• Authors: Gandjar Kiswanto, Vinsensius Ricko, S. Suntoro
• Keywords: Five-Axis Milling, Inclination Angle, Machined Surface Quality

References

[1] Marciniak K., Influence of Surface Shape on Admissible Tool Positions in 5-axis Face Milling, Computer Aided Design, 1987, vol. 19, no. 5, pp.233-236.

DOI: 10.1016/0010-4485(87)90260-0

[2] Altan T., Lilly B.W., Kruth J.P., König W., Tönshoff H.K., Van Luttervelt C, Khairy A.B., 1993, Advanced techniques for die and mold manufacturing, Annals of the CIRP, 42/2: 707-716.

DOI: 10.1016/s0007-8506(07)62533-5

[3] Jensen C.G., Mullins S.H., Anderson D.C., Scallop elimination based on precise 5-axis tool placement, orientation and step-over calculations, ASME-Advances in Design Automation, 1993, vol. 65-2, pp.535-544.

DOI: 10.1115/detc1993-0428

[4] Kruth J. -P., Klewais P., Optimisation and Dynamic Adaptation of the Cutter Inclination during 5-axis Milling of Sculptured Surfaces, Annals of CIRP, 1994, vol. 43/1, pp.443-448.

DOI: 10.1016/s0007-8506(07)62249-5

[5] Lee, Y.S., Ji H., Surface Interrogation and Machining Strip Evaluation for 5-axis CNC Die and Mold Machining, International Journal of Production Research, 1997, vol. 35, no. 1, pp.225-252.

DOI: 10.1080/002075497196064

[6] Kruth J. -P., Lauwers B., Dotremont J., Dejonghe P., Optimised NC-Toolpath Generation for 5-axis Machining of Complex Surfaces, Proceeding of the SSM-conference (Machining Impossible Shape) - Detroit USA, 1998 pp.343-350.

DOI: 10.1007/978-0-387-35392-0_35

[7] Kiswanto G., Lauwers B., Kruth J. -P, Tool Path Generation for 5-axis Milling based on Faceted Model, Journal Machine Engineering, Vol. 2 No. 1-2 2002, ISSN 1642-6568 Open and Global Manufacturing Design 2002, pp.99-109.

DOI: 10.1016/s0007-8506(07)60537-x

[8] Lauwers, B., Kiswanto, G., Kruth, J. -P, Inclination Angle Control for Optimal Tool Orientation in 5-Axis Milling Based on Faceted Models, Proc. of CIRP International Seminar on Intelligent Computation in Manufacturing Engineering, Ischia, 3-5 July 2002, pp.267-272.

DOI: 10.1016/s0007-8506(07)60537-x

[9] Jun C.S., Cha K., Lee Y. -S., Optimizing tool orientations for 5-axis machining by configuration-space search method, Computer Aided Design, 35(2003) 549-566.

DOI: 10.1016/s0010-4485(02)00077-5

[10] A Antoniadis, B. Bilialis, C. Savakis, E. Maravelakis and G. Petropoulos, Influence of Machining Inclination Angle on Surface Quality in Ball-end Milling, Proceeding AMPT 2003, 8-11 July 2003, Dublin, Ireland.

[11] Lauwers, B., Kiswanto, G., Kruth, J. -P, Gouging Avoidance in Five-Axis Tool Path Generation by a Simultaneous Change of Inclination and Screw Angle, CIRP Anals (2006).

DOI: 10.1016/s0007-8506(07)60537-x

[12] Shi Guo Han and Jun Zhao, Effect of Tool Inclination Angle on Surface Quality in 5-axis Ball-end Milling, Advanced Material Research Vol. 97-101, pp.2080-2084, (2010).

DOI: 10.4028/www.scientific.net/amr.97-101.2080

[13] L.L. Li, Y.F. Zhang, H.Y. Li, and L. Geng, Generating Tool-Path with Smooth Posture Change for Five-axis Sculptured Surface Machining based on Cutter's Accessibility Map, International Journal of Advanced Manufacturing Technology, Vol. 53, 699-709, (2011).

DOI: 10.1007/s00170-010-2849-2

[14] R.V. Fleisig, A.D. Spence, A Constant Feed and Reduced Angular Acceleration Interpolation Algorithm for Multi-axis Machining, Computer Aided Design, Vol. 33, pp.1-15, (2001).

DOI: 10.1016/s0010-4485(00)00049-x