Modeling errors forming abnormal tool marks on a twisted ruled surface in flank milling of the five-axis CNC

Abstract

The complex surface machining quality is related to the capacity of the control system, servo drive and mechanical transmission in five-axis CNC machining. The unsuitable parameters result in surface contour errors and other processing abnormal phenomena such as tool marks and corrugated surface. In this paper a twisted ruled surface in flank milling is analyzed. The construction features of surface and the tool path characteristic of the specimen are listed. The surface cutting velocity is deduced considering the constraints of the acceleration, jerk and other control parameters and the smoothness is modeled. The individual tracking error acquired from servo feed system model is converted to the contour error by homogeneous transformation matrix and Frenet frame, and abnormal tool marks in flank milling are suggested. The cutting experiments conform to simulation; the effect of the dynamic indicators of the CNC machine tool is explored by the abnormal marks on the machined parts. This approach provides a support for designing specimens and investigating machine tool dynamics performance in working accuracy test.

Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation

“…The local stiffness change of thin-walled parts can maintain the material removal rate and stability of cutting force by changing the feed [23]. Xie [24] analyzed surface structure and tool path characteristics of the workpiece, and considered the constraints of acceleration and impact. The smoothness model of thin-walled parts was derived, the contour error was obtained and the surface roughness was evaluated.…”