Integrated Simulation System for 5-axis Milling Cycles

Multi axis milling is a promising technology for machining of complex geometries and surfaces. Thanks to the additional rotary axis, it provides flexibility to overcome the accessibility issues. However, the process becomes more complicated in terms of geometry, mechanics and dynamics due to the additional degrees of freedom and ball nose end mills. In this study, mechanics and stability of 5-axis ball end milling operations is simulated throughout a given toolpath. The cutting tool-workpiece engagement boundary is calculated and workpiece is represented using distance field approach. Distance field approach features very low computational time, close to real-time simulation. The cutting forces are modeled using orthogonal-to-oblique transformation. Stability limits are estimated in frequency domain.