Research On Feed Parameters Optimization Technology For5-axis Flank Milling

The five-axis flank milling is an important five-axis CNC machining process. Through a lot of research, theoretical and experimental research of a cooperative enterprise which is using the five-axis flank milling process in their actual production, a five-axis flank milling feed parameter optimization method is proposed. The mainly research work is as follows:(1) Five-axis flank milling basic theory research which based on the stable effective tool axis sweep area rate(the sweep area per unit of time by the tool axis line segment which corresponding to the effective cutting edge). Based on the multi-body system theory, a five-axis CNC machine tool’s kinematic model is created. Also, a cutting force model of flank milling process is created. The average cutting force of one turn is used to describe the changes of the cutting force. The relational model between the effective tool axis sweep area rate and the average cutting force of one turn is deduced.(2) The theoretical and experimental methods research which based on the motion characteristic of the machine feed axis. By analyzing the acceleration and deceleration principle of the machine feed axis of five-axis CNC machine tool, the detection method and the test data analysis method of the motion characteristic of the machine feed axis is proposed.(3) A feed parameter optimization method of five-axis flank milling process is created which based on the stable effective tool axis sweep area rate and the motion characteristic of the machine feed axis. The optimization method can keep the effective tool axis sweep area rate stable. Also, it can remain the cutting force stable. At the same time the feed rate is optimized based on the motion characteristic of the machine feed axis, including the speed and the allowed processing error constrain optimization and the acceleration constrain optimization.(4) A software for the feed parameter optimization method is developed. Testing experiment for the motion characteristic of the machine feed axis and the contrast cutting test of the feed parameter optimization have done to verify the effectiveness of the feed parameter optimization method.A series of experiments show that the proposed five-axis flank milling feed parameter optimization method could keep the cutting force of five-axis flank milling process stable, optimize the cutting process with the motion characteristic of the machine feed axis concerned, improve the surface quality of the workpiece, and have good theoretical and practical significance.