Grant: Research Tools and Instruments - Category 1 (<$150,000)

The aerospace, die and mold industry widely use 5-axis machining operations. The automotive and power train industry use mill-turn machines to produce parts on one set-up. The applicants, who conduct research in the mathematical modeling of machining operations, propose to model 5-axis milling and turn-milling operations. The ultimate objective of the research is to predict and optimize 5-axis milling operations ahead of costly, physical trials in the shops. As the tool travels along a 5-axis path, the three linear and two rotary drives change positions. The cutter-part engagement conditions also change along the tool path as a function of part geometry and cutter dimensions. As a result, the magnitudes and directions of the cutting forces vary, which can be measured only by the proposed rotating dynamometer attached to the spindle. The applicants will model the force and vibration, and will validate their mathematical models using the proposed dynamometer. The most optimal depth of cut, width of cut, speed and feed will be selected based on the experimentally proven, 5-axis cutting models. The proposed equipment will enable the researchers to expand the current Virtual Machining Systems research at UBC towards the 5-axis machining of dies, molds, and aircraft parts.