The traditional stability analysis by only considering cutting depth-spindle speed lobe diagram is appropriate for parameters optimization and efficiency improvement of the five-axis ball-end milling. However due to the complicated cutter-workpiece engagement (CWE) of bull-nose end cutter in five-axis milling, the maximal cutting depth may not produce the maximal material removal rate (MRR). Thus, the traditional stability analysis is not suitable for the five-axis bull-nose end milling in parameters optimization, and this paper presents a new stability analysis method to analyze the effect of tool orientation on machining efficiency for five-axis bull-nose end milling. In the establishing of stability prediction model, coordinate transformation and vector projection method are adopted to identify the CWE and dynamic cutting thickness, and the geometrical relationship of frequency response function (FRF) coordinate system and cutting force coordinate system with variable tool orientation is derived to establish the conversion of FRF and cutting force in stability equation. Based on the CWE sweeping, the cutting area along the feed direction is calculated to realize the critical MRR analysis in the stability model. Based on the established stability prediction model, the effects of tool orientation on critical cutting depth and MRR considering the chatter constraint are analyzed and validated by the cutting experiments, respectively. The lead-tilt diagram, which not only gives the boundary of stability region but also describes the contour line for MRR, is proposed for the further tool orientation optimization.
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December 2018
Research-Article
Stability Prediction Based Effect Analysis of Tool Orientation on Machining Efficiency for Five-Axis Bull-Nose End Milling
Xiaowei Tang,
Xiaowei Tang
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: txwysxf@126.com
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: txwysxf@126.com
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Zerun Zhu,
Zerun Zhu
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: eonpig@hust.edu.cn
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: eonpig@hust.edu.cn
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Rong Yan,
Rong Yan
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: yanrong@hust.edu.cn
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: yanrong@hust.edu.cn
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Chen Chen,
Chen Chen
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: chenchen1990@hust.edu.cn
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: chenchen1990@hust.edu.cn
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Fangyu Peng,
Fangyu Peng
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China;
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: zwm8917@263.net
Huazhong University of Science and Technology,
Wuhan 430074, China;
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: zwm8917@263.net
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Mingkai Zhang,
Mingkai Zhang
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: zmk0509@163.com
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: zmk0509@163.com
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Yuting Li
Yuting Li
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: lytwhut@163.com
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: lytwhut@163.com
Search for other works by this author on:
Xiaowei Tang
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: txwysxf@126.com
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: txwysxf@126.com
Zerun Zhu
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: eonpig@hust.edu.cn
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: eonpig@hust.edu.cn
Rong Yan
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: yanrong@hust.edu.cn
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: yanrong@hust.edu.cn
Chen Chen
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: chenchen1990@hust.edu.cn
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: chenchen1990@hust.edu.cn
Fangyu Peng
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China;
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: zwm8917@263.net
Huazhong University of Science and Technology,
Wuhan 430074, China;
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: zwm8917@263.net
Mingkai Zhang
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: zmk0509@163.com
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: zmk0509@163.com
Yuting Li
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: lytwhut@163.com
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: lytwhut@163.com
1Corresponding authors.
Manuscript received May 22, 2018; final manuscript received September 3, 2018; published online October 8, 2018. Assoc. Editor: Tony Schmitz.
J. Manuf. Sci. Eng. Dec 2018, 140(12): 121015 (16 pages)
Published Online: October 8, 2018
Article history
Received:
May 22, 2018
Revised:
September 3, 2018
Citation
Tang, X., Zhu, Z., Yan, R., Chen, C., Peng, F., Zhang, M., and Li, Y. (October 8, 2018). "Stability Prediction Based Effect Analysis of Tool Orientation on Machining Efficiency for Five-Axis Bull-Nose End Milling." ASME. J. Manuf. Sci. Eng. December 2018; 140(12): 121015. https://doi.org/10.1115/1.4041426
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