A new method for 5-axis flank computer numerically controlled (CNC) machining is proposed. A set of tappered ball-end-mill tools (aka conical milling tools) is given as the input and the flank milling paths within user-defined tolerance are returned. Thespace of lines that admit tangential motion of an associated truncated cone along a general, doubly curved, free-form surface is explored. These lines serve as discrete positions of conical axes in 3D space. Spline surface fitting is used to generate a ruled surface that represents a single continuous sweep of a rigid conical milling tool. An optimization-based approach is then applied to globally minimize the error between the design surface and the conical envelope. The milling simulations are validated with physical experiments on two benchmark industrial datasets, reducing significantly the execution times while preserving or even reducing the milling error when compared to the state-of-the-art industrial software.

Highly accurate 5-axis flank CNC machining with conical tools

Vibration singularity analysis for milling tool condition monitoring

Application of Measurement Systems in Tool Condition Monitoring of Milling: A Review of measurement science approach

Titanium alloy Ti6Al4V is a distinctive material widely used in modern industries since it has low density and high strength, and performs well in high temperature and corrosion resistance. However, relatively little work on cutting mechanism of ultra-precision machining (UPM) of Ti6Al4V has been conducted. In this study, a series of cutting tests have been carried out to study the cutting mechanism of Ti6Al4V in UPM. The effects of cutting conditions (spindle speed, feed rate, and depth of cut) on surface roughness and cutting forces have been discussed for improving surface quality. In addition, one finite element model (FEM) was proposed to investigate chip formation and cutting forces in UPM, which has been supported well by cutting tests.

Study on cutting mechanism of Ti6Al4V in ultra-precision machining

New mechanistic cutting force model for milling additive manufactured Inconel 718 considering effects of tool wear evolution and actual tool geometry

This paper presented a study of the relationship between cutting force and tool flank wear of solid carbide tool during the wet end milling Ti6Al4V. The modeling of 3D cutting force in end milling considering tool flank wear was discussed, which showed that for the given cutting conditions, tool geometries, and workpiece material, cutting force under the tool flank wear effect can be predicted easily and conveniently. In addition, the experimental work of end milling Ti6Al4V with solid carbide tool was developed to investigate the relationship between cutting force and tool flank wear, and comparison between experimental results and predicted results was discussed. The results showed that the proposed mathematical model can help to predict 3D cutting force under the tool flank wear effect with high accuracy.

Modeling of cutting force under the tool flank wear effect in end milling Ti6Al4V with solid carbide tool

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Modeling of cutting force under the tool flank wear effect in end milling Ti6Al4V with solid carbide tool