MATEC Web Conf.
Volume 237, 20182018 3rd International Conference on Design, Mechanical and Material Engineering (D2ME 2018)
|Number of page(s)||7|
|Section||Chapter 1: Mechanical Engineering|
|Published online||26 November 2018|
A solid-analytical-based model for extracting cutter-workpiece engagement in 5-axis flank machining
1 School of Mechanical Engineering, Tongji University, 201804 Shanghai, China.
2 Sino-German Advanced Manufacturing Technology Center (CDHK), Tongji University, 201804 Shanghai, China.
3 WBK Institute of Production Science, Karlsruhe Institute of Technology, 76131 Karlsruhe, Germany.
a Corresponding author: firstname.lastname@example.org
5-axis flank milling is applied extensively in aerospace, die-molds, and automotive industries because of high efficient material removal rate. Commercial CAM software can only simulate the tool path and collision at present, but cannot handle with cutting force during cutting process due to the variable geometrical cutter workpiece engagement (CWE) region of 5-axis milling. This paper presents a novel solid analytical model for extracting the CWE maps. The CWE is obtained analytically by performing Boolean operations between the cutter and in-process-workpiece (IPW) at any given cutter location (CL) point, instead of using the cutter and the removal volume. The proposed process simulation method could identify the CWE efficiently and precisely for general cutting tools. Finally, the CWE boundaries are mapped from a 3D space into a 2D plane defined by the immersion angle and the axial depth of a given cutter. The proposed solution can be easily integrated into the CAM software for predicting milling force and optimizing parameters in 5-axis milling.
© The Authors, published by EDP Sciences, 2018
This is an Open Access article distributed under the terms of the Creative Commons Attribution License 4.0, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
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