title: Generic simulation approach for multi-axis machining. Part 2: model calibration and feed rate scheduling
abstract: For Part 1 see ibid. vol.124 (2002). This is the second part of a two-part paper presenting a new methodology for analytically simulating multi-axis machining of complex sculptured surfaces. The first section of this paper offers a detailed explanation of the model calibration procedure. A new methodology is presented for accurately determining the cutting force coefficients for multi-axis machining. The force model presented in Part 1 is reformulated so that the cutting force coefficients account for the effects of feed rate, cutting speed, and a complex cutting edge design. Experimental results are presented for the calibration procedure. Model verification tests were conducted with these cutting force coefficients. These tests demonstrate that the predicted forces are within 5% of experimentally measured forces. Simulated results are also shown for predicting dynamic cutting forces and static/dynamic tool deflection. The second section of the paper discusses how the modeling methodology can be applied for feed rate scheduling in an industrial application. A case study for process optimization of machining an airfoil-like surface is used for demonstration. Based on the predicted instantaneous chip load and/or a specified force constraint, the feed rate scheduling is utilized to increase the metal removal rate. The feed rate scheduling implementation results in a 30% reduction in machining time for the airfoil-like surface
keyphrases: generic simulation model calibration feed rate scheduling complex sculptured surfaces cutting force coefficients force model cutting edge design optimization metal removal rate multiple axis machining