Evaluation of multi-axis machining processes based on macroscopic engagement simulation

Process planning and process design to identify stable process areas is nowadays characterized by time-consuming correction loops, where the number of iterations and the effort involved are mostly from the experience and knowledge of process designer. This requires on the one hand additional planning steps as deriving process parameters and secondly an evaluation of the achieved product quality. By using the macro simulation model introduced in this paper, the computational complexity to obtain significant process knowledge is decreased and thus made accessible more easily. Detailed tool-workpiece engagement is calculated through the presented model, which co-relates to mechanical and thermal stresses on the tool. Based on the calculations the process can be designed by reducing the tool load in the course of the process. This way, the tool life of the used milling cutters can be significantly increased resulting in an increase of process robustness and efficiency, thereby reducing used resources