Title: Simultaneous five-axis finishing milling of TiAl6V4 centrifugal compressor blades: a dynamic evaluation of lead and tilt angles variation

Authors: Guilherme Oliveira De Souza, Adelson Ribeiro De Almeida Jr., Jefferson De Oliveira Gomes, Fabiana Eloisa Passador

Addresses: CIMATEC – Centro Integrado de Manufatura e Tecnologia, SENAI BA, Av. Orlando Gomes, 1845, Piata, 41650-010, Salvador, BA, Brazil. ' CCM – Centro de Competencia em Manufatura, ITA, CTA, Praca Marechal Eduardo Gomes, 50, Vila das Acacias, 12228-900, Sao Jose dos Campos, SP, Brazil. ' CCM – Centro de Competencia em Manufatura, ITA, CTA, Praca Marechal Eduardo Gomes, 50, Vila das Acacias, 12228-900, Sao Jose dos Campos, SP, Brazil. ' Escola Santos Dumont, SENAI SP, Rua Pedro Rachid, 304, Santana, 12211-180, Sao Jose dos Campos, SP, Brazil

Abstract: The most used orientation method for five-axis milling operations by commercial CAM software is the Sturz method in which two angles, lead and tilt, are defined for the tool axis in relation to the surface normal. Lead and tilt angles have significant effects on process mechanics and dynamics. In this paper, the effects of the variation of lead and tilt angles on tool tip contact and surface finish quality were analysed. These effects were investigated through an experimental test in which a TiAl6V4 impeller was machined. It is shown that the cutting geometry, mechanics and dynamics vary drastically and non-linearly with these angles. It is observed that adding multi-frequency effects in the solution has marginal influence on the stability diagrams for five-axis ball-end milling operations due to effects of the ball-end milling geometry on the engagement region. The machined surface quality and the process stability can be quite different for various combinations of lead and tilt angles.

Keywords: simultaneous five-axis milling; turbine blades; impellers; machining vibrations; lead angle; tilt angle; centrifugal compressors; five-axis machining; tool tip contact; surface finish; surface quality; titanium alloys; ball end milling; process stability; cutting geometry.

DOI: 10.1504/IJMMS.2011.041475

International Journal of Mechatronics and Manufacturing Systems, 2011 Vol.4 No.3/4, pp.322 - 336

Available online: 24 Jul 2011 *

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