Cutting layer and cutting forces in a 5-axis milling of sculptured surfaces using the toroidal cutter

Abstract

The purpose of this article was to evaluate the significance of the influence of five- axis orientation parameters of a toroidal cutter axis and the geometrical parameters of the machined sculptured surface on the intersection of the cut layer in a 5-axis machining. An impact assessment was performed by simulating concave-convex and convex-concave surfaces using a discrete method of direct transformation in a CAD environment. It was shown that only the radius of curvature of the surface in the feed direction and the angle of the tool axis affected the change in the intersection of the cutting layer. Subsequently, experimental tests were conducted that aimed at determining the mathematical models of the influence of these important parameters on the components of the cutting force. The object of the experimental studies was a convex and concave surface of a turbine blade of Inconel 718 alloy. The R300-016B20L-08L Sandvik Coromant toroid cutter was used for the tests. Based on the results of the study it was found that the lead angle in the machining of the convex surface and concave turbine blade should be continuously varied with the change of radius of curvature in the direction of the machined surface profile