Optimization of five-axis finish milling using a virtualmachine tool

Abstract

The five axis finish milling process is a complex process. The request surface quality and accuracy should be produced within as short time as is possible. This three main process characteristics - quality, accuracy and machining time - remain in a close relation. They are affected with dynamic properties of the machine tool structure, the feed drive properties including their cascade control, the control system interpolator properties and the NC code shape. Thus the appropriate optimization of all related parameters through the whole chain is a time and material demanding operation. The paper describes how the virtual machine tool is created involving the properties of the machine structure, the feed drives and their cascade control. This machine tool model is connected with the real or virtual control system core. The tests for verification of the control system functionality are presented. Virtual simulation of the process is demonstrated on the use case. The process chain parameters are optimized using the virtual machine tool for increasing productivity. Simulation and experimental results are compared.