Research On Stability Of Five-axis Milling With The Fillet-end Cutter

With the continuous development of science and technology,complex curved surfaces in growing numbers are applied in the high technology industry,the manufacturing technology of key parts will be more strict than before.The five-axis machining technology is widely used in high-end technology manufacturing due to it owns flexible tool position and excellent efficiency comparing to the traditional processing technology.Five-axis machining is a complex physical process,the milling quality and processing efficiency are severely restricted by the phenomena of cutting force,deformation,vibration and so on.Currently,most of the researches on stability analysis are based on three-axis vertical milling and cutting forces are aimed at five-axis ball-end milling machining.However,the researches on five-axis machining of fillet-end mill cutter and stability analysis are relatively less.Therefore,this paper focuses on dynamic characteristics of five-axis machining,taking the fillet-end mill cutter as processing tool,taking into account the cutter run-out,predicting milling force and analyzing milling stability.This paper main research contents are as follows:Through the geometrical model of the fillet-end milling cutter,the instantaneous cutting thickness model considering the cutter run-out is established.The influence of the cutter run-out on the instantaneous cutting thickness and the change regulation of the cutting edge of each cutter are analyzed.And the effect of the cutter run-out on cutting force is discussed based on the established cutting force model.The cutter-workpiece engagement is extracted by using the solid-analytical method in different cutter posture angles.The discrete start and exit angles for predicting the milling force.The five-axis cutting force model is used to predict the milling force under obtaining discrete start and exit angles.And the accuracy of cutting force model is verified by experiments.On the basis of establishing dynamic model of the fillet-end cutter,the Gear method and the Hamming method for prediction of milling stability are presented.The two methods have high accuracy and computational efficiency.The influence of different cutter size and the cutter run-out on the milling stability is discussed by using Hamming method,which shows that the ball-end cutter,the fillet-end cutter and the cutter run-out can improve the milling stability under certain conditions.The dynamics model of five-axis milling with fillet-end cutter is established,the start and exit angles are obtained by using the discrete method in different cutting depth.The difference between start-exit angles of force cutting and milling stability prediction are analyzed.Stability lobes diagrams which provide a certain theoretical basis when optimal selecting processing parameters in five-axis milling and which show that posture angles can change the milling stability domain are simulated by MATLAB under different start-exit angles that are gained by using CAM software in different posture angles.