Serbest yüzeyli parçaların küresel uçlu freze ile beş eksenli frezelemenin modellemesi

Five-axis milling of freeform geometries is challenging and costly due to the complexities of the machining operation. Understanding the mechanics of the cutting process helps the process engineers select the best cutting parameters in order to increase the productivity. The main aim of this research thesis is to shed light on the mechanics of five-axis milling operation for complex workpieces such as blades, impellers and blisks in order to increase the efficiency of the process. The contribution of this research is introducing a cutting force model based on a novel cuter-workpiece engagement and a new cutting force coefficient identification approach. Based on the developed cutting force model, the efficiency of the process is improved by scheduling the feedrate, modeling the tool deflection, identifying the tool orientation and modelling the surface generation. The effect of lead and tilt angles on cutting force, torque, deflection and surface quality in five-axis ball-end milling of flexible parts is thoroughly investigated. Based on that, a new strategy is proposed to select the appropriate tool orientation to avoid suboptimal products. The novelty of the proposed strategy lies in presenting a mechanics-based reference map that suggests the appropriate tool orientation considering above-mentioned parameters. The effectiveness of the approach is demonstrated experimentally.