Title: Analytical methods for increased productivity in 5-axis ball-end milling

Authors: Erdem Budak, L. Taner Tunc, Erhan Budak

Addresses: Manufacturing Research Laboratory, Faculty of Engineering and Natural Sciences, Sabanci University, Istanbul, Turkey. ' Manufacturing Research Laboratory, Faculty of Engineering and Natural Sciences, Sabanci University, Istanbul, Turkey. ' Manufacturing Research Laboratory, Faculty of Engineering and Natural Sciences, Sabanci University, Istanbul, Turkey

Abstract: Five-axis ball-end milling is a technology that many industries such as aerospace, automotive and die/mould employ for complex surface machining. Cutting forces, form errors and chatter vibrations are among the most important limitations in five-axis ball-end milling. Since they are generally not calculated beforehand, machining a product with five-axis ball-end milling may involve iterations on the machine tool due to process problems. In order to eliminate this, process models can be used. An analytical methodology is presented in this paper for modelling of five-axis ball-end milling. The method includes process models, and an interface between process models and CAM software. Process models for cutting force, form error and chatter stability predictions are used in the process planning stage to predict potential problems beforehand, and optimise machining conditions. The process models are presented and verified by experimental tests. The presented method is implemented in a simulation software, and applied in machining of industrial parts where productivity increase for example cases is demonstrated.

Keywords: five-axis milling; ball end milling; cutting force; form errors; chatter vibration; stability; five-axis machining; modelling; process models; CAM; process planning; simulation.

DOI: 10.1504/IJMMS.2011.041471

International Journal of Mechatronics and Manufacturing Systems, 2011 Vol.4 No.3/4, pp.238 - 265

Received: 01 Jul 2010
Accepted: 12 Jul 2010
Published online: 07 Mar 2015 *

Full-text access for editors Full-text access for subscribers Purchase this article Comment on this article