Optimization of five-axis finish milling using a virtualmachine tool

Abstract

Five-axis finish milling is a complex process. The requested surface quality and accuracy must be produced in the shortest possible time. The three main process characteristics - quality, accuracy and machining time - are closely related one to each other. They are affected by the dynamic properties of the machine tool structure, the feed drive properties including cascade control, the control system interpolator properties and the NC code. Thus the appropriate optimization of all related parameters throughout the entire chain is demanding in terms of both time and material. This paper describes the creation of a virtual machine tool that takes into account the properties of the machine structure, feed drives and their cascade control. This machine tool model is connected to the CNC control system kernel. Tests used to verify control system functionality are presented. A virtual simulation of the process is demonstrated on the use case. The process chain parameters are optimized using the virtual machine tool to increase productivity. The simulation and experimental results are compared.