Analysis of tool orientation for 5-axis ball-end milling of flexible parts

This article investigates the effects of lead and tilt angles in 5-axis ball-end milling of flexible freeform aerospace parts by considering process mechanics. In current CAM technology, tool posture is determined by geometrical analysis only. However, in high-performance 5-axis milling, not only the geometry, but also the mechanics of the process is critical. Therefore, a new and comprehensive mechanics-based strategy is proposed for selection of tool postures considering process parameters such as cutting force, torque, part vibration, and surface quality. Effectiveness of the proposed strategy is validated by conducting experiments on 5-axis ball-end milling of flexible freeform structures.