In five-axis milling, the bottom edge of a flat end mill is probably involved in cutting when the lead angle of tool axis changes to negative. The mechanistic model will lose accuracy if the bottom edge cutting effect is neglected. In this paper, an improved mechanistic model of five-axis machining with a flat end mill is presented to accurately predict cutting forces by combining the cutting effects of both side and bottom edges. Based on the kinematic analysis of the radial line located at the tool bottom part, the feasible contact radial line (FCRL) is analytically extracted. Then, boundaries of the bottom cutter-workpiece engagements (CWEs) are obtained by intersecting the FCRL with workpiece surfaces and identifying the inclusion relation of its endpoints with the workpiece volume. Next, an analytical method is proposed to calculate the cutting width and the chip area by considering five-axis motions of the tool. Finally, the method of calibrating bottom-cutting force coefficients by conducting a series of plunge milling tests at various feedrates is proposed, and the improved mechanistic model is then applied to predict cutting forces. The five-axis milling with a negative lead angle and the rough machining of an aircraft engine blisk are carried out to test the effectiveness and practicability of the proposed model. The results indicate that it is essential to take into account the bottom edge cutting effect for accurate prediction of cutting forces at tool path zones where the tool bottom part engages with the workpiece.
Skip Nav Destination
Article navigation
November 2016
Research-Article
Mechanistic Modeling of Five-Axis Machining With a Flat End Mill Considering Bottom Edge Cutting Effect
Zhou-Long Li,
Zhou-Long Li
State Key Laboratory of Mechanical
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: lzl@sjtu.edu.cn
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: lzl@sjtu.edu.cn
Search for other works by this author on:
Li-Min Zhu
Li-Min Zhu
State Key Laboratory of Mechanical
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: zhulm@sjtu.edu.cn
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: zhulm@sjtu.edu.cn
Search for other works by this author on:
Zhou-Long Li
State Key Laboratory of Mechanical
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: lzl@sjtu.edu.cn
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: lzl@sjtu.edu.cn
Li-Min Zhu
State Key Laboratory of Mechanical
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: zhulm@sjtu.edu.cn
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: zhulm@sjtu.edu.cn
1Corresponding author.
Manuscript received December 12, 2015; final manuscript received May 13, 2016; published online June 24, 2016. Assoc. Editor: Radu Pavel.
J. Manuf. Sci. Eng. Nov 2016, 138(11): 111012 (11 pages)
Published Online: June 24, 2016
Article history
Received:
December 12, 2015
Revised:
May 13, 2016
Citation
Li, Z., and Zhu, L. (June 24, 2016). "Mechanistic Modeling of Five-Axis Machining With a Flat End Mill Considering Bottom Edge Cutting Effect." ASME. J. Manuf. Sci. Eng. November 2016; 138(11): 111012. https://doi.org/10.1115/1.4033663
Download citation file:
Get Email Alerts
2024 Reviewers
J. Manuf. Sci. Eng
NoodlePrint: Cooperative Multi-Robot Additive Manufacturing With Helically Interlocked Tiles
J. Manuf. Sci. Eng (June 2025)
Related Articles
Spiral Tool Path Generation Method on Mesh Surfaces Guided by Radial Curves
J. Manuf. Sci. Eng (July,2018)
An Accurate Method for Determining Cutter-Workpiece Engagements in Five-Axis Milling With a General Tool Considering Cutter Runout
J. Manuf. Sci. Eng (February,2018)
Related Proceedings Papers
Related Chapters
Computer-Aided Process Planning and Data Collection
Manufacturing Engineering: Principles for Optimization, Third Edition
Computer Aided Machine Design
Computer Aided Design and Manufacturing
Modeling of Cutting Force in Vibration-Assisted Machining
Vibration Assisted Machining: Theory, Modelling and Applications