Virtual Dynamics Model for Five-Axis Machining of Thin-Walled Blades

Abstract

Abstract The five-axis ball-end milling dynamics of thin-walled blades is presented. The cutting forces are predicted from the ball-end mill–blade geometry engagement maps along the toolpath. The Frequency Response Function (FRF) of the thin-walled blade is predicted using Finite Element shell elements, and it is updated along the toolpath as the metal is removed. The predicted cutting forces are applied on both the workpiece and tool FRFs to predict the forced vibrations and chatter stability at each tool location. A simplified method to update the cutter-workpiece engagement (CWE) is used to obtain the three-dimensional stability lobe diagram at each desired point on the blade. The integrated model is used to simulate the five-axis machining of thin-walled blades in the digital environment. The proposed digital model is experimentally validated by machining a series of thin-walled rectangular plates and a twisted fan blade.