Non-uniform flank wear prediction and tool orientation optimization for ball-end tool 5-axis machining based on real cutting length calculation

Tool wear is an important issue to be considered in machining analysis and improvement. The non-uniform flank wear of ball-end tool is a commonly existing phenomenon in ball-end milling but has been less concerned so far. In this paper, the non-uniform flank wear of ball-end tools in 5-axis machining based on real cutting length calculation is discussed. Firstly, the flank wear model of differential cutting edge is constructed considering the real cutting length (RCL). Secondly, the RCL is obtained with intersection point calculation according to the cutter workpiece contact analysis. Then, the distributions of accumulated RCL and flank wear are analyzed and the similarity between them is found, based on which a tool orientation optimization method is given to improve the tool wear conditions. Lastly, machining experiments are carried out to validate the efficiency and accuracy of the prediction method. The results of the calculation and experiment show that the tool orientation optimization can help to reduce the maximum flank wear.