Cutting dynamics research on the five-axis machining of thin curved surface with barrel-taper-ball milling cutter

The use of blisk is essential for improving the performance of aviation engines, and the cutting of blade curved surface is the core of blisk CNC machining. In response to the problem of traditional ball end milling cutter and barrel milling cutter that is difficult to take into account the quality and efficiency of blade machining, this article proposes a barrel-taper-ball milling cutter. The contour of the new cutter’s barrel taper area is more fit with the blade curved surface, which is conducive to obtaining a larger cutting step and a tiny scallop height. Further, for the problem of weak rigidity thin-wall curved surface machining chatter, the cutting dynamics model of the five-axis machining of the barrel-taper-ball milling cutter is established. Through the determination of the material contact criterion of cutting edge micro element, a cutting geometry analysis algorithm is proposed. By deducing the oblique cutting forces of barrel taper area and ball end area, exploring the time-varying characteristics of blade modes, the multiple frequently method theory is extended to construct the stability machining parameter domain. Experiments and simulations indicate that the cutting step of the new cutter under the same surface roughness can increase by seven times, the solution error of cutting geometry on blade curved surface is only 0.5%, the prediction error of three-dimensional cutting force is about 4.95%, and the optimized stability parameter domain can achieve machining without chatter.