A high efficiency force predicting method of multi-axis machining propeller blades

Abstract

Accurate cutting force prediction is a vital factor to analyze vibration, deformation, and residual stress in the machining. Meanwhile, it provides important reference for feed speed and tool orientation optimization. The problems of predicting accuracy and efficiency of cutting forces are serious especially for the 5-axis machining. Thus a rapid cutting force prediction method based on the classic mechanical model is proposed to calculate the 5-axis machining cutting forces. In the method, the cutting forces are directly calculated by elementary function integral, which can improve the calculating efficiency, compared with discretization and accumulation method. The experiments were conducted to verify the validity of the proposed method. The results show that the proposed method increases efficiency nearly 86 times compared with the z-map method and 20 times compared with the cutter/workpiece engagement boundary method and keeps a good accuracy.