Generic Simulation Approach for Multi-Axis Machining, Part 2: Model Calibration and Feed Rate Scheduling

Author:

Bailey T.1,Elbestawi M. A.1,El-Wardany T. I.2,Fitzpatrick P.2

Affiliation:

1. McMaster Manufacturing Research Institute, McMaster University, Hamilton, Ont, Canada

2. United Technologies Research Center, East Hartford, CT

Abstract

This is the second part of a two-part paper presenting a new methodology for analytically simulating multi-axis machining of complex sculptured surfaces. The first section of this paper offers a detailed explanation of the model calibration procedure. A new methodology is presented for accurately determining the cutting force coefficients for multi-axis machining. The force model presented in Part 1 of this paper is reformulated so that the cutting force coefficients account for the effects of feed rate, cutting speed, and a complex cutting edge design. Experimental results are presented for the calibration procedure. Model verification tests were conducted with these cutting force coefficients. These tests demonstrate that the predicted forces are within 5% of experimentally measured forces. Simulated results are also shown for predicting dynamic cutting forces and static/dynamic tool deflection. The second section of the paper discusses how the modeling methodology can be applied for feed rate scheduling in an industrial application. A case study for process optimization of machining an airfoil-like surface is used for demonstration. Based on the predicted instantaneous chip load and/or a specified force constraint, feed rate scheduling is utilized to increase metal removal rate. The feed rate scheduling implementation results in a 30% reduction in machining time for the airfoil-like surface.

Publisher

ASME International

Subject

Industrial and Manufacturing Engineering,Computer Science Applications,Mechanical Engineering,Control and Systems Engineering

Reference17 articles.

1. Budak, E., Altintas, Y., and Armarego, E. J. A., 1996, “Prediction of Milling Force Coefficients from Orthogonal Cutting Data,” ASME J. Manuf. Sci. Eng., 118, pp. 216–224.

2. Ehmann, K. F., Yun, W. S., and Cho, D. W., 1999, “Determination of Constant 3D Cutting Force Coefficients and of Runout Parameters in End Milling,” Transactions of NAMRI/SME, Vol. 27, pp. 87–92.

3. Yucesan, G., and Altintas, Y., 1993, “Mechanics of Ball End Milling Process,” ASME J. Manuf. Sci. Eng., 64, pp. 543–551.

4. Imani, B., 1998, “Model Based Die Cavity Machining Simulation Methodology,” Ph.D. thesis, McMaster University, Hamilton, ON.

5. Kapoor, S. G., DeVor, R. E., Zhu, R., Gajjela, R., Parakkal, G., and Smithey, D., 1998, “Development of Mechanistic Models for the Prediction of Machining Performance: Model-Building Methodology,” CIRP International Workshop on Modeling of Machining Operations, No. 2, pp. 1–12.

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