The paper presents a method of forecasting the product surface topography after five-axis machining with a lens-shaped end-mill. Surface roughness is one of the key parameters considered when assessing the effectiveness of the machining process, especially in the aviation, automotive, tooling and medical equipment industries. The developed method, the first published, presented in the paper is based on the analytical equations of the trajectory of the cutting edge motion, on the basis of which the cutter action surface is generated. The developed model takes into account: cutting depth, cutting width, feed, lead angle and radial runout. Experimental studies were conducted using three different materials: 40HM steel, Al7035 aluminum alloy and Ti Grade 5 titanium alloy. Various values of the cutting width parameters and different feeds were used in the tests. Based on the results of the experimental tests, an empirical model (response surface model) was determined and was then used to verify the simulation model. The simulation results and the results of experimental tests were compared and conclusions were drawn regarding the developed models. The developed models supported by numerical simulation can be used to approximately estimate the influence of the width of cut $b_r$ and feed $f_t$ on selected height characteristics $S_a$ and $\widehat{Sz}$ of the geometric structure of the surface (GSS) after machining with a lens-shaped end-mill in terms of the process parameters adopted in the tests. It was found that the influence of the $f_t$ on the $S_a$ and $\widehat{Sz}$ is greater for small values of $b_r$. The effect of $b_r$ is greater with lower $f_t$ values. The cutting width $b_r$ has the greatest influence on $S_a$ and $\widehat{Sz}$, and $f_t$ and the interaction of these parameters has the least influence.

The study investigates the problem of modeling cutting-force components through response surface methodology and reports the results of an investigation into the impact of machining parameters on the cutting mechanics of polymer–matrix composites. The novelty of this study is the modeling of cutting forces and the determination of mathematical models of these forces. The models describe the values of forces as a function of the milling parameters. In addition, the cutting resistance of the composites was determined. The influence of the material and rake angle of individual tools on the cutting force components was also determined. Measurements of the main (tangential) cutting force showed that, using large rake angles for uncoated carbide tools, one could obtain maximum force values that were similar to those obtained with polycrystalline diamond tools with a small rake angle. The results of the analysis of the tangential component of cutting resistance showed that, regardless of the rake angle, the values range from 140 N to 180 N. An analysis of the feed component of cutting resistance showed that the maximum values of this force ranged from 46 N to 133 N. The results showed that the highest values of the feed component of cutting resistance occurred during the machining of polymer composites with carbon fibers and that they were most affected by feed per tooth. It was also shown that the force models determined during milling with diamond insert tools had the highest coefficient of determination in the range of 0.90–0.99. The cutting resistance analysis showed that the values tested are in the range of 3.8 N/mm² to 15.5 N/mm².

This article presents an analysis and the modeling of cutting forces in the process of oscillation milling of side surfaces of workpieces made of hardened steel. In addition, the impact of the oscillation machining method on cutting forces was analyzed, taking into account feed optimization. A sinusoidal function was used to describe the trajectory of the tool in order to induce the oscillatory motion. The study is based on a set of 34 cutting tests using four end-mill cutters, each characterized by a unique combination of feed rate and sinusoidal downward and upward angles. This constitutes a novel approach to sine wave period selection. Empirical mathematical models of the cutting forces were developed using the response surface method. The results demonstrate that the sinusoidal trajectory of the tool movement, together with optimization of the feed rate, leads to a reduction in fluctuations and the stabilization of cutting forces, and an approximately 30% increase in the efficiency of this machining process.

Artykuł Dynamiczna symulacja obróbki pięcioosiowej z wykorzystaniem wirtualnej maszyny w systemie NX * | Mechanik Miesięcznik Naukowo-Techniczny