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A general method for instantaneous undeformed chip thickness calculation in five-axis milling based on Boolean operations

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Abstract

Instantaneous undeformed chip thickness (IUCT) plays a critical role in optimizing and monitoring of five-axis milling processes, as it determines machining precision and tool life by affecting cutting forces. Analytical and numerical methods have been widely used for IUCT calculation. However, these methods have some deficiencies, such as solving the unsolvable transcendental equations, modeling the complex cutting edge trajectory, and poor adaptability for five-axis milling. Therefore, a Boolean method which consists of subtraction and intersection operations is developed. First, the blank for the current cutting edge is obtained by the Boolean subtraction operation between the workpiece and the swept volume that produced by the front cutting edges. Second, the Boolean intersection operation is executed between the blank and the auxiliary edge entity (AEE) that corresponding to the tool edge. Then, the IUCT of each cutting edge or each cutting point can be deduced based on the Boolean result with the known blank geometry, tool geometry, tool path, and machining parameters. The method is verified by milling force experiments. It is an efficient, accurate, and general method because it does not need to establish complex mathematical or numerical models. The calculated IUCT will promote the optimizing and monitoring of five-axis milling processes.

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Data availability

All data generated or analyzed during this study were available by emailing to author. (liguochaolaile@126.com).

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Funding

This study was supported by the National Natural Science Foundation of China (No. 51605207) and the Natural Science Foundation of Jiangsu Province of China (No. BK20160563)

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Authors and Affiliations

  1. School of Mechanical Engineering, Jiangsu University of Science and Technology, Zhenjiang, 212003, People’s Republic of China

    Guochao Li, Yunlong Liu, Donghao Zhao, Lei Dai, Honggen Zhou & Xuwen Jing

  2. Jiangsu Provincial Key Laboratory of Advanced Manufacturing for Marine Mechanical Equipment, Jiangsu University of Science and Technology, Zhenjiang, 212003, People’s Republic of China

    Guochao Li, Yunlong Liu, Donghao Zhao, Lei Dai, Honggen Zhou & Xuwen Jing

Authors
  1. Guochao Li
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  2. Yunlong Liu
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  3. Donghao Zhao
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  4. Lei Dai
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  5. Honggen Zhou
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  6. Xuwen Jing
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Contributions

Guochao Li built the Boolean method which consists of subtraction and intersection operations to calculate the IUCT, and was a major contributor in writing the manuscript. Yunlong Liu realized the procedure by applying NX 8.0 secondary development technology. Donghao Zhao and Lei Dai carried out the milling force experiments. Honggen Zhou and Xuwen Jing helped to read and approve the final manuscript.

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Correspondence to Guochao Li.

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Li, G., Liu, Y., Zhao, D. et al. A general method for instantaneous undeformed chip thickness calculation in five-axis milling based on Boolean operations. Int J Adv Manuf Technol 116, 2325–2334 (2021). https://doi.org/10.1007/s00170-021-07576-4

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  • DOI: https://doi.org/10.1007/s00170-021-07576-4

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