High efficiency calculation of cutter-workpiece engagement in five-axis milling using distance fields and envelope theory

Ma, Hengyuan; Liu, Wei; Zhou, Xionghui; Niu, Qiang; Kong, Chuipin

doi:10.1016/j.jmapro.2021.06.055

Cited by 15 publications

(2 citation statements)

References 30 publications

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“…The main methods of solving it include the solid model method, the analytical method and the discrete differential method. The solid model method is used to perform boolean operations on the vertices, edges and faces of the model in simulation to obtain the meshing situation of the tool and the workpiece [8].…”

Section: Introductionmentioning

confidence: 99%

Theoretical and experimental study of cutting forces under tool flank interference in ultra-precision diamond milling

Liu

Wei²,

Zhang³

et al. 2023

Preprint

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In ultra-precision diamond milling (UPDM), the cutting force as an indicator of machining stability deserves to be discussed extensively. However, most studies have focused on the direct material removal under tool rake cutting, not considering tool flank interference in UPDM. In this study, a theoretical and experimental investigation has been conducted to discuss cutting forces under the tool flank interference in UPDM. Firstly, an analysis model of the interference space between tool flank and workpiece was built up to study the tool flank interference positions. Secondly, a kinematic model for the tool cutting motion was constructed to discuss the instantaneous uncut chip thicknesses (IUCT) under the tool flank interference. Moreover, a cutting force model was proposed to reveal the relationship between the cutting forces and IUCT. Finally, a series of milling tests were carried out in UPDM for the validity of the theoretical results. The theoretical and experimental results revealed that the tool flank interference would take place to deform surface generation and induce sudden changes of the cutting forces in UPDM. The tangential cutting force (Fr) reflects the dominant IUCT, and the radial cutting force (Fr) shows an extremely high sensitivity to the IUCT under tool flank interference, while (Fr) has little correlation with IUCT under tool rake cutting, even negligible. This research work gives a deep insight into the cutting forces with surface generation under the tool flank interference in UPDM.

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Section: Introductionmentioning

confidence: 99%

Theoretical and experimental study of cutting forces under tool flank interference in ultra-precision diamond milling

Liu

Wei²,

Zhang³

et al. 2023

Preprint

View full text Add to dashboard Cite

show abstract

“…Discrete modeling methods aim to simplify complex solid modeling calculations while retaining required precision by applying surface and volume representation methods that typically originate in the computer graphics domain. Most commonly applied variants of these methods include the Z-buffer [21][22][23] and distance field representations (see, e.g., [24][25][26][27][28]).…”

Section: Introductionmentioning

confidence: 99%

Chatter-free milling strategy of a slender Blisk blade via stock distribution optimization and continuous spindle speed change

Petráček

Falta

Stejskal

et al. 2022

Int J Adv Manuf Technol

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The machining process of Blisk blades poses multiple challenges due to high requirements on surface quality and precision combined with high dynamic compliance of the thin-walled blades. Avoidance of chatter is thus of high priority in Blisk blade machining. However, the geometry of the Blisk blade array where the tool must fit between individual blades significantly limits the possibilities of controlling stability through the relative orientation of the tool and workpiece. Thus, the main parameters that can be used to control the stability of the process are the distribution of stock allowance and the spindle speed. Due to the effect of material removal on the blade’s dynamic properties, spindle speed needs to be adjusted throughout the machining process to keep it within the continuously changing stability gaps. This paper describes in detail an optimization procedure for the design of stock allowance distribution in such a way that a continuous spindle speed modulation is possible that avoids chatter throughout the machining process by maintaining spindle speeds within stability gaps. The presented algorithm uses finite element analysis software to simulate the effects of stock allowance distribution and material removal on workpiece dynamical properties. This information is then coupled with a stability model based on the Jacobian of the cutting force with respect to the regenerative deflection to identify the varying stability gaps throughout the machining process. The proposed method was experimentally verified.

show abstract

Theoretical and experimental study of cutting forces under tool flank interference in ultra-precision diamond milling

Liu

Wei

Zhang

et al. 2023

Int J Adv Manuf Technol

View full text Add to dashboard Cite

High efficiency calculation of cutter-workpiece engagement in five-axis milling using distance fields and envelope theory

Cited by 15 publications

References 30 publications

Theoretical and experimental study of cutting forces under tool flank interference in ultra-precision diamond milling

Theoretical and experimental study of cutting forces under tool flank interference in ultra-precision diamond milling

Chatter-free milling strategy of a slender Blisk blade via stock distribution optimization and continuous spindle speed change

Theoretical and experimental study of cutting forces under tool flank interference in ultra-precision diamond milling

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