Scholarlink

<p>This paper proposes a new method that combines both analytical and discrete approaches to extract information about the contact between the workpiece and the cutting tool during the 5-axis milling process of turbine blades, specifically using Ti-6Al-4V as the workpiece material. In the proposed model, the authors categorize the boundary regions into three distinct types of curves to accurately determine the Cutting Work Engagement (CWE) area. This CWE extraction model is developed based on data collected from tool paths and the complex surfaces of Ti-6Al-4V turbine blades, a material known for its high strength-to-weight ratio and excellent corrosion resistance, yet challenging machinability. Practical machining experiments validate the proposed method by revealing CWE variations under different cutting conditions. Unlike traditional approaches, the hybrid model combines analytical formulations with discrete geometry processing to accurately extract CWE in 5-axis milling. Through NURBS-based surface modelling and NC code interpretation, the method enhances the fidelity of tool–surface interaction, especially for complex geometries like turbine blades, thereby improving tool path prediction and cutting force modelling. Additionally, the model's capability to extract the CWE area under varying conditions, such as cutting depth and tool position, is assessed through cutting force analysis. Extracting CWE BS1 Boundary Data helps achieve more stable machining conditions and results in surface roughness values (Ra) of 1.35–1.67&#xa0;µm, which are approximately one-half to one-third of those obtained using BS2 and BS3 boundaries. The final results indicate that the proposed model effectively extracts information about the contact between the cutting tool and Ti-6Al-4V workpiece in the 5-axis milling process, achieving an error margin of less than 0.2&#xa0;mm, even under varying machining conditions.</p> Graphical Abstract <p></p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

A hybrid analytical-discrete approach for extracting cutting tool-workpiece contact information in 5-axis turbine blade milling

  • 期刊论文

  • 发表日期：

    2025年7月2日

查看全文
  • Nguyen Van Que,
  • Dung Hoang Tien,
  • Nguyen Duy Trinh,
  • Do Minh Hien,
  • Kieu Van Quang,
  • Nguyen Huy Kien

摘要

This paper proposes a new method that combines both analytical and discrete approaches to extract information about the contact between the workpiece and the cutting tool during the 5-axis milling process of turbine blades, specifically using Ti-6Al-4V as the workpiece material. In the proposed model, the authors categorize the boundary regions into three distinct types of curves to accurately determine the Cutting Work Engagement (CWE) area. This CWE extraction model is developed based on data collected from tool paths and the complex surfaces of Ti-6Al-4V turbine blades, a material known for its high strength-to-weight ratio and excellent corrosion resistance, yet challenging machinability. Practical machining experiments validate the proposed method by revealing CWE variations under different cutting conditions. Unlike traditional approaches, the hybrid model combines analytical formulations with discrete geometry processing to accurately extract CWE in 5-axis milling. Through NURBS-based surface modelling and NC code interpretation, the method enhances the fidelity of tool–surface interaction, especially for complex geometries like turbine blades, thereby improving tool path prediction and cutting force modelling. Additionally, the model's capability to extract the CWE area under varying conditions, such as cutting depth and tool position, is assessed through cutting force analysis. Extracting CWE BS1 Boundary Data helps achieve more stable machining conditions and results in surface roughness values (Ra) of 1.35–1.67 µm, which are approximately one-half to one-third of those obtained using BS2 and BS3 boundaries. The final results indicate that the proposed model effectively extracts information about the contact between the cutting tool and Ti-6Al-4V workpiece in the 5-axis milling process, achieving an error margin of less than 0.2 mm, even under varying machining conditions.

Graphical Abstract