Skip to main content
SpringerLink
Log in

Modeling, simulation, and optimization of five-axis milling processes

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The five-axis milling is widely applied to complex surface machining. When cutting forces of milling processes increase, the consequent workpiece and tool deflections may result in poor machining quality and high processing cost. There are a lot of researches on three-axis milling processes simulation, but very few about five-axis milling. To solve these disadvantages, this paper presents an integrated system containing modeling, simulation, and optimization of five-axis milling processes. The system has three major applications: (1) simulation verification of milling processes, (2) cutting forces prediction, and (3) cutting parameters (feedrate) optimization. The material removal process simulation used for verifying the five-axis milling is based on the three-dexel (depth element) model, and the cutter-workpiece engagement regions are extracted from the geometric model. According to the extracted cutter-workpiece engagement regions, the instantaneous cutting forces could be predicted. The feedrate is off-line modified for balancing the given maximum or the reference cutting forces with the predicted cutting forces on different machining steps. The developed system is validated experimentally to show that the modeling, simulation, and optimization methods could improve the accuracy and efficiency of five-axis milling processes.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Baptista R, Antune Simöes. (2000) Three and five axes milling of sculptured surfaces. J Mater Process Technol 103:398–403

    Article  Google Scholar 

  2. Ozturk E, Tunc LT, Budak E. (2009) Investigation of lead and tilt angle effects in 5-axis ball-end milling processes. Int J Mach Tools Manuf 49:1053–1062

    Article  Google Scholar 

  3. Jaehun J, Kwangsoo K. (1999) Generating tool paths for free-form pocket machining using z-buffer-based Voronoi diagrams. Int J Adv Manuf Technol 15:182–187

    Article  Google Scholar 

  4. Hui KC (1994) Solid sweeping in image space-application in NC simulation. Vis Comput 10:306–316

    Article  Google Scholar 

  5. Surmann T. (2006) Geometrisch-physikalische Simulation der Prozessdynamik für das fünfachsige Fräsen von Freiformflächen. Vulkan Verlag, Germany

    Google Scholar 

  6. Cheng YZ, Xiong CH, Ye T, Cheng HK. (2011) Five-axis milling simulation based on B-rep model. Lect Notes Comput Sci 7101:22–32

    Article  Google Scholar 

  7. Jang DG, Kim K, Jung JM (2000) Voxel-based virtual multi-axis machining. Int J Adv Manuf Technol 16:709–713

    Article  Google Scholar 

  8. Kim YH, Ko SL. (2006) Improvement of cutting simulation using the octree method. Int J Adv Manuf Technol 28:1152–1160

    Article  Google Scholar 

  9. Zhu WH, Lee YS. (2004) Dexel-based force-torque rendering and volume updating for 5-DOF haptic product prototyping and virtual sculpting. Comput Ind 55:125–145

    Article  Google Scholar 

  10. Weinert K, Zabel A, Ungemach E, Odendahl S. (2008) Improved NC path validation and manipulation with augmented reality methods. Prod Eng 2:371–376

    Article  Google Scholar 

  11. Yang M, Park H. (1991) The prediction of cutting force in ball end milling. Int J Mach Tools Manufact 31:45–54

    Article  Google Scholar 

  12. Tai CC, Fhu KH. (1994) A predictive force model in ball-end milling including eccentricity effects. Int J Mach Tools Manuf 34:959–979

    Article  Google Scholar 

  13. Tai CC, Fhu KH. (1995) Model for cutting forces prediction in ball-end milling. Int J Mach Tools Manuf 35:511–534

    Article  Google Scholar 

  14. Kim GM, Cho PJ, Chu CN. (2000) Cutting force prediction of sculptured surface ball-end milling using Z-map. Int J Mach Tools Manuf 40:277–291

    Article  Google Scholar 

  15. Lazoglu I. (2003) Sculpture surface machining: a generalized model of ball-end milling force system. Int J Mach Tools Manuf 43:453–462

    Article  Google Scholar 

  16. Lazoglu I. (2001) Generalized mechanistic force system model of ball end milling force system for sculpture surface machining. Am Soc Mech Eng Manuf Eng Div MED 12:31–38

    Google Scholar 

  17. Ozturk B, Lazoglu I, Erdim H. (2006) Machining of free-form surfaces. Part II: Calibration and forces. Int J Mach Tools Manuf 46:736–746

    Article  Google Scholar 

  18. Altintas Y, Lee P. (1995) Combined mechanics and dynamics of ball end milling. ASME Winter Annu Meet MED 2:657– 677

    Google Scholar 

  19. Lee P, Altintas Y. (1996) Prediction of ball end milling forces from orthogonal cutting data. Int J Mach Tools Manuf 36:1059– 1072

    Article  Google Scholar 

  20. Fontaine M, Devillez A, Moufki A, Dudzinski D. (2006) Predictive force model for ball-end milling and experimental validation with a wavelike form machining test. Int J Mach Tools Manuf 46:367–380

    Article  Google Scholar 

  21. Ning L, Veldhuis SC. (2006) Mechanistic modeling of ball end milling including tool wear. J Manuf Processes 8:21–28

    Article  Google Scholar 

  22. Bouzid Saï W Ben Said M, Saï K. (2009) An investigation of cutting forces in machining with worn ball-end mill. J Mater Process Technol 209:3198–3217

    Article  Google Scholar 

  23. Wu BH Yan X, Luo M, Gao G. (2013) Cutting force prediction for circular end milling process. Chinese Journal of Aeronautics 26:1057–1063

    Article  Google Scholar 

  24. Subrahmanyam KVR, Wong YS, Hong GS, Huang S. (2010) Cutting force prediction for ball nose milling of inclined surface. Int J Adv Manuf Technol 48:23–32

    Article  Google Scholar 

  25. Wei ZC, Wang MJ, Cai YJ, Wang SF. (2013) Prediction of cutting force in ball-end milling of sculptured surface using improved Z-map. Int J Adv Manuf Technol 68:1167–1177

    Article  Google Scholar 

  26. Huang T, Zhang XM, Han D. (2013) Decoupled chip thickness calculation model for cutting force prediction in five-axis ball-end milling. Int J Adv Manuf Technol

  27. Zhang LQ. (2011) Process modeling and toolpath optimization for five-axis ball-end milling based on tool motion analysis. Int J Adv Manuf Technol 57:905–916

    Article  Google Scholar 

  28. Lazoglu I, Boz Y, Erdimb H. (2011) Five-axis milling mechanics for complex free form surfaces. CIRP Ann Manuf Technol 60:117–120

    Article  Google Scholar 

  29. Kaymarkci M, Lazoglu I, Murtezaoglu Y. (2006) Machining of complex sculptured surfaces with feedrate scheduling. Int J Manuf Res 1:157–175

    Article  Google Scholar 

  30. Erdim H, Lazoglu I, Kaymakci M. (2007) Free-form surface machining and comparing feedrate scheduling strategies. Mach Sci Technol 11:117–133

    Article  Google Scholar 

  31. Qian L, Yang BD, Lei S. (2008) Comparing and combining off-line feedrate rescheduling strategies in free-form surface machining with feedrate acceleration and deceleration. Rob Comput Integr Manuf 24:796–803

    Article  Google Scholar 

  32. Zhang LQ, Feng JC, Wang YH, Chen M. (2009) Feedrate scheduling strategy for free-form surface machining through an integrated geometric and mechanistic model. Int J Adv Manuf Technol 40:1191–1201

    Article  Google Scholar 

  33. Lee HU, Cho DW (2003) An intelligent feedrate scheduling based on virtual machining. Int J Adv Manuf Technol 22:873–882

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Mechanical Engineering and Automation, Northeastern University, Shenyang, People’s Republic of China

    Xuewei Zhang, Tianbiao Yu & Wanshan Wang

Authors
  1. Xuewei Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Tianbiao Yu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Wanshan Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Xuewei Zhang.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhang, X., Yu, T. & Wang, W. Modeling, simulation, and optimization of five-axis milling processes. Int J Adv Manuf Technol 74, 1611–1624 (2014). https://doi.org/10.1007/s00170-014-6075-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-014-6075-1

Keywords

Search

Navigation