Initial Tool Orientation Set-up for 5-Axis Flank Milling Based on Faceted Models

Abstract

One of the factors affecting the effectiveness of machining time of 5-axis miling is the method being used. By using flank milling method, as one of the optimized processes to make a workpiece, the time required for the process becomes shorter.This research is aimed at developing the method for determining the initial orientation of the tool for a sculptured surface on the basis of faceted model. By determining cc-point as the basis for positioning the tool on the surface of the workpiece, the cutting direction is formed from the nearest cc-point in the XY flat plane direction of the faceted model at the spatial coordinate. The positioning of the tool is initially based on the Local Coordinate System developed by the cross product between the normal vector nat each cc-point and cutting direction vector Ffrom one cc-point to the other. The cross product resulted is a tangent vector Tof the plane formed from the normal vector and cutting direction. The orientation of the tool is formed and defined by an inclination angle (α) and a screw angle (β). Maximizing the cutting volume and avoiding gouging at each cc-point during the flank milling are carried out through optimal adjustment of these two rotational angles. Furthermore, when the adjustment of rotational angles cannot resolve the gouging, appropriate tool lifting along the normal vector is conductedhis method is very much applicable for flank milling having the basis of data in the form of faceted models.