General Cutting Dynamics Model for Five-Axis Ball-End Milling Operations

Five-axis ball-end milling is used extensively to machine parts with sculptured surfaces. This paper presents the general cutting dynamics model of the ball-end milling process for machine tools with different five-axis configurations. The structural dynamics of both the tool and workpiece are considered for the prediction of chatter stability at each tool location along the tool path. The effects of tool–workpiece engagement and tool axis orientation are included in the model. By sweeping the spindle speeds, the chatter-free spindle speeds are selected followed by the prediction of forced vibrations in five-axis milling of thin-walled, flexible parts. The proposed model has been experimentally illustrated to predict the chatter stability and forced vibrations on a table-tilting five-axis computer numerical control machine tool.

[1]  Yaser Mohammadi,et al.  Optimization of material removal rate in milling of thin-walled structures using penalty cost function , 2019, International Journal of Machine Tools and Manufacture.

[2]  Yusuf Altintas,et al.  Analytical Modeling of Process Damping in Machining , 2019, Journal of Manufacturing Science and Engineering.

[3]  Jixiang Yang,et al.  Virtual prediction and constraint of contour errors induced by cutting force disturbances on multi-axis CNC machine tools , 2019, CIRP Annals.

[4]  Jixiang Yang,et al.  Identification of workpiece location on rotary tables to minimize tracking errors in five-axis machining , 2018 .

[5]  Oguzhan Tuysuz.  Modeling of machining thin-walled aerospace structures , 2018 .

[6]  Jianhui Li,et al.  Rapid dynamics prediction of tool point for bi-rotary head five-axis machine tool , 2017 .

[7]  Kevin M. Lynch,et al.  Modern Robotics: Mechanics, Planning, and Control , 2017 .

[8]  Yusuf Altintas,et al.  Chatter free tool orientations in 5-axis ball-end milling , 2016 .

[9]  Yusuf Altintas,et al.  Generalized modelling of cutting tool geometries for unified process simulation , 2016 .

[10]  Yusuf Altintas,et al.  Generalized mechanics and dynamics of metal cutting operations for unified simulations , 2016 .

[11]  Y. Altintas,et al.  Generalized kinematics of five-axis serial machines with non-singular tool path generation , 2013 .

[12]  Guillem Quintana,et al.  Chatter in machining processes: A review , 2011 .

[13]  Han Ding,et al.  A full-discretization method for prediction of milling stability , 2010 .

[14]  Erdem Ozturk,et al.  Dynamics and Stability of Five-Axis Ball-End Milling , 2010 .

[15]  Mahdi Eynian,et al.  Chatter stability of turning and milling with process damping , 2010 .

[16]  Lutfi Taner Tunc,et al.  Extraction of 5-axis milling conditions from CAM data for process simulation , 2009 .

[17]  Yusuf Altintas,et al.  Virtual Five-Axis Flank Milling of Jet Engine Impellers—Part I: Mechanics of Five-Axis Flank Milling , 2008 .

[18]  Yusuf Altintas,et al.  Identification of dynamic cutting force coefficients and chatter stability with process damping , 2008 .

[19]  Gábor Stépán,et al.  Updated semi‐discretization method for periodic delay‐differential equations with discrete delay , 2004 .

[20]  Yusuf Altintas,et al.  Mechanics and dynamics of general milling cutters.: Part I: helical end mills , 2001 .

[21]  Yusuf Altintas,et al.  Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design , 2000 .

[22]  Tony L. Schmitz,et al.  Predicting High-Speed Machining Dynamics by Substructure Analysis , 2000 .

[23]  Eiji Shamoto,et al.  Analytical Prediction of Stability Lobes in Ball End Milling , 1999 .

[24]  Yusuf Altintas,et al.  Mechanics and Dynamics of Ball End Milling , 1998 .

[25]  Yusuf Altintas,et al.  Prediction of ball-end milling forces from orthogonal cutting data , 1996 .

[26]  Frank Chongwoo Park,et al.  A Lie Group Formulation of Robot Dynamics , 1995, Int. J. Robotics Res..

[27]  Yusuf Altintas,et al.  Analytical Prediction of Stability Lobes in Milling , 1995 .

[28]  Richard M. Murray,et al.  A Mathematical Introduction to Robotic Manipulation , 1994 .

[29]  J. Tlusty,et al.  Stability Lobes in Milling , 1983 .

[30]  J. Denavit,et al.  A kinematic notation for lower pair mechanisms based on matrices , 1955 .