AUTOMATED FIVE-AXIS TOOL PATH GENERATION BASED ON DYNAMIC ANALYSIS

Abstract

In this thesis, automated 5-axis tool path generation considering true dynamic factors (cutting force and chatter) is studied. The research objectives are to develop models for predicting cutting forces and chatter in 5-axis milling and algorithm for optimizing the cutter posture at each cutter contact point in tool path generation. When chatter in 5-axis machining can be predicted, posture stability (PSG) can be constructed. Then, combining the accessibility-map together, chatter- and interference-free (CIF) cutter posture range can be identified. Optimal cutter posture from CIF-map towards the minimal maximum deflection cutting force (MDC-F) can be determined and subsequently optimal tool path considering true machining dynamics can be generated. The proposed cutting force prediction and chatter prediction methods in 5-axis milling have been validated by experiments. The CIF-map construction has been studied by simulations. It represents a significant step in 5-axis tool path generation from static model to dynamic mode.