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Methodic of Rational Cutting Conditions Determination for 3-D Shaped Detail Milling Based on the Process Numerical Simulation

[+] Author Affiliations
Igor Kiselev, Sergey Voronov

Bauman Moscow State Technical University, Moscow, Russia

Paper No. DETC2014-34894, pp. V006T10A075; 11 pages
  • ASME 2014 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference
  • Volume 6: 10th International Conference on Multibody Systems, Nonlinear Dynamics, and Control
  • Buffalo, New York, USA, August 17–20, 2014
  • Conference Sponsors: Design Engineering Division, Computers and Information in Engineering Division
  • ISBN: 978-0-7918-4639-1
  • Copyright © 2014 by ASME


The paper is devoted for the analysis of the dynamics effect on the 5-axis milling process of flexible details. The integrated model of milling dynamics composed by block principle in the paper is presented. The model consist of: 1) dynamical model of tool; 2) dynamical model of machined detail based on Finite Element Method (FEM); 3) phenomenological model of cutting forces and 4) algorithm of geometry modeling for instant machined chip thickness calculation. Regeneration mechanism of cutting and calculation of the machined surface are into this algorithm embedded. The elaborated model is adapted for 5-axis processing of the profiled details with 3-D complex geometry. Alteration of workpiece dynamic characteristics while the allowance removal is considered by the special algorithm of FEM grid changing based on the results of cutting geometry modeling. The results of modeling give us opportunity determine cutting forces, estimate the machined surface quality, calculate the magnitude and the character of tool and detail vibrations under the specified cutting conditions. The conception of increasing the process quality and the machinability for 3-D shaped details machining is offered in the paper. Applying the specified efficient conditions the undesired dynamical effects can be excluded on the base of the results of multi-variant simulation for milling dynamics varying the technological parameters at the different region of the processing route.

Copyright © 2014 by ASME



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