Abstract
Five-axis ball-end milling is used extensively to machine parts with sculptured surfaces. This paper presents the general cutting dynamics model of the ball-end milling process for machine tools with different five-axis configurations. The structural dynamics of both the tool and workpiece are considered for the prediction of chatter stability at each tool location along the tool path. The effects of tool–workpiece engagement and tool axis orientation are included in the model. By sweeping the spindle speeds, the chatter-free spindle speeds are selected followed by the prediction of forced vibrations in five-axis milling of thin-walled, flexible parts. The proposed model has been experimentally illustrated to predict the chatter stability and forced vibrations on a table-tilting five-axis computer numerical control machine tool.
Issue Section:
Research Papers
Keywords:
five-axis machine tools,
milling process,
chatter stability,
forced vibration,
machine tool dynamics,
machining processes,
modeling and simulation
Topics:
Chatter,
Cutting,
Dynamics (Mechanics),
Machine tools,
Milling,
Stability,
Vibration,
Machining
References
1.
Altintas
, Y.
, and Lee
, P.
, 1998
, “Mechanics and Dynamics of Ball End Milling
,” ASME J. Manuf. Sci. Eng.
, 120
(4
), pp. 684
–692
. 10.1115/1.28302072.
Quintana
, G.
, and Ciurana
, J.
, 2011
, “Chatter in Machining Processes: A Review
,” Int. J. Mach. Tools Manuf.
, 51
(5
), pp. 363
–376
. 10.1016/j.ijmachtools.2011.01.0013.
Altintas
, Y.
, 2012
, Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design
, Cambridge University Press
, New York
.4.
Tlusty
, J.
, Zaton
, W.
, and Ismail
, F.
, 1983
, “Stability Lobes in Milling
,” CIRP Ann.—Manuf. Technol.
, 32
(1
), pp. 309
–313
. 10.1016/S0007-8506(07)63411-85.
Altintas
, Y.
, and Budak
, E.
, 1995
, “Analytical Prediction of Stability Lobes in Milling
,” CIRP Ann.
, 44
(1
), pp. 357
–362
. 10.1016/S0007-8506(07)62342-76.
Insperger
, T.
, and Stépán
, G.
, 2004
, “Updated Semi-Discretization Method for Periodic Delay-Differential Equations With Discrete Delay
,” Int. J. Numer. Methods Eng.
, 61
(1
), pp. 117
–141
. 10.1002/nme.10617.
Ding
, Y.
, Zhu
, L.
, Zhang
, X.
, and Ding
, H.
, 2010
, “A Full-Discretization Method for Prediction of Milling Stability
,” Int. J. Mach. Tools Manuf.
, 50
(5
), pp. 502
–509
. 10.1016/j.ijmachtools.2010.01.0038.
Altintas
, Y.
, Shamoto
, E.
, Lee
, P.
, and Budak
, E.
, 1999
, “Analytical Prediction of Stability Lobes in Ball End Milling
,” ASME J. Manuf. Sci. Eng.
, 121
(4
), pp. 586
–592
. 10.1115/1.28330649.
Zhang
, J.
, Li
, J.
, Xie
, Z.
, Du
, C.
, Gui
, L.
, and Zhao
, W.
, 2017
, “Rapid Dynamics Prediction of Tool Point for Bi-Rotary Head Five-Axis Machine Tool
,” Precis. Eng.
, 48
, pp. 203
–215
. 10.1016/j.precisioneng.2016.12.00310.
Schmitz
, T. L.
, 2000
, “Predicting High-Speed Machining Dynamics by Substructure Analysis
,” CIRP Ann.—Manuf. Technol.
, 49
(1
), pp. 303
–308
. 10.1016/S0007-8506(07)62951-511.
Tunc
, L. T.
, and Budak
, E.
, 2009
, “Extraction of 5-Axis Milling Conditions From CAM Data for Process Simulation
,” Int. J. Adv. Manuf. Technol.
, 43
(5–6
), pp. 538
–550
. 10.1007/s00170-008-1735-712.
Ozturk
, E.
, and Budak
, E.
, 2010
, “Dynamics and Stability of Five-Axis Ball-End Milling
,” ASME J. Manuf. Sci. Eng.
, 132
(2
), pp. 237
–247
. 10.1115/1.400103813.
Tuysuz
, O.
, and Altintas
, Y.
, 2019
, “Analytical Modeling of Process Damping in Machining
,” ASME J. Manuf. Sci. Eng.
, 141
(6
), p. 061006
. 10.1115/1.404331014.
Sun
, C.
, and Altintas
, Y.
, 2016
, “Chatter Free Tool Orientations in 5-Axis Ball-End Milling
,” Int. J. Mach. Tools Manuf.
, 106
, pp. 89
–97
. 10.1016/j.ijmachtools.2016.04.00715.
Ringgaard
, K.
, Mohammadi
, Y.
, Merrild
, C.
, Balling
, O.
, and Ahmadi
, K.
, 2019
, “Optimization of Material Removal Rate in Milling of Thin-Walled Structures Using Penalty Cost Function
,” Int. J. Mach. Tools Manuf.
, 145
, p. 103430
. 10.1016/j.ijmachtools.2019.10343016.
Yang
, J.
, Aslan
, D.
, and Altintas
, Y.
, 2018
, “Identification of Workpiece Location on Rotary Tables to Minimize Tracking Errors in Five-Axis Machining
,” Int. J. Mach. Tools Manuf.
, 125
, pp. 89
–98
. 10.1016/j.ijmachtools.2017.11.00917.
Denavit
, J.
, and Hartenberg
, R. S.
, 1955
, “A Kinematic Notation for Lower-Pair Mechanisms Based on Matrices
,” ASME J. Appl. Mech.
, 22
(2
), pp. 215
–221
.18.
Lynch
, K. M.
, and Park
, F. C.
, 2017
, Modern Robotics Mechanics, Planning, and Control
, Cambridge University Press
, New York
, http://hades.mech.northwestern.edu/index.php/Modern_Robotics19.
Yang
, J.
, and Altintas
, Y.
, 2013
, “Generalized Kinematics of Five-Axis Serial Machines With Non-Singular Tool Path Generation
,” Int. J. Mach. Tools Manuf.
, 75
, pp. 119
–132
. 10.1016/j.ijmachtools.2013.09.00220.
Murray
, R. M.
, Li
, Z.
, and Sastry
, S. S.
, 1994
, A Mathematical Introduction to Robotic Manipulation
, CRC Press
, Boca Raton, FL
.21.
Tuysuz
, O.
, 2018
, Modeling of Machining Thin-Walled Aerospace Structures, Ph.D. Dissertation
, University of British Columbia
, Vancouver, Canada
.22.
Kilic
, Z. M.
, and Altintas
, Y.
, 2016
, “Generalized Modelling of Cutting Tool Geometries for Unified Process Simulation
,” Int. J. Mach. Tools Manuf.
, 104
, pp. 14
–25
. 10.1016/j.ijmachtools.2016.01.00723.
24.
Lee
, P.
, and Altintas
, Y.
, 1996
, “Prediction of Ball-End Milling Forces From Orthogonal Cutting Data
,” Int. J. Mach. Tools Manuf.
, 36
(9
), pp. 1059
–1072
. 10.1016/0890-6955(95)00081-X25.
Kilic
, Z. M.
, and Altintas
, Y.
, 2016
, “Generalized Mechanics and Dynamics of Metal Cutting Operations for Unified Simulations
,” Int. J. Mach. Tools Manuf.
, 104
, pp. 1
–13
. 10.1016/j.ijmachtools.2016.01.00626.
Engin
, S.
, and Altintas
, Y.
, 2001
, “Mechanics and Dynamics of General Milling Cutters. Part I: Helical End Mills
,” Int. J. Mach. Tools Manuf.
, 41
(15
), pp. 2195
–2212
. 10.1016/S0890-6955(01)00045-127.
Eynian
, M.
, 2010
, Chatter Stability of Turning and Milling With Process Damping
, Ph.D. Dissertation, University of British Columbia
, Vancouver, Canada
.28.
Ferry
, W. B.
, and Altintas
, Y.
, 2008
, “Virtual Five-Axis Flank Milling of Jet Engine Impellers—Part I: Mechanics of Five-Axis Flank Milling
,” ASME J. Manuf. Sci. Eng.
, 130
(1
), p. 011005
. 10.1115/1.281576129.
Altintas
, Y.
, Yang
, J.
, and Kilic
, Z. M.
, 2019
, “Virtual Prediction and Constraint of Contour Errors Induced by Cutting Force Disturbances on Multi-Axis CNC Machine Tools
,” CIRP Ann.
, 68
(1
), pp. 377
–380
. 10.1016/j.cirp.2019.04.01930.
31.
Altintas
, Y.
, Eynian
, M.
, and Onozuka
, H.
, 2008
, “Identification of Dynamic Cutting Force Coefficients and Chatter Stability With Process Damping
,” CIRP Ann.—Manuf. Technol.
, 57
(1
), pp. 371
–374
. 10.1016/j.cirp.2008.03.04832.
Park
, F. C.
, Bobrow
, J. E.
, and Ploen
, S. R.
, 1995
, “A Lie Group Formulation of Robot Dynamics
,” Int. J. Rob. Res.
, 14
(6
), pp. 609
–618
. 10.1177/027836499501400606Copyright © 2020 by ASME
You do not currently have access to this content.
