A New Dynamics Analysis Model for Five-Axis Machining of Curved Surface Based on Dimension Reduction and Mapping

Abstract The equipment used in various fields contains an increasing number of parts with curved surfaces of increasing size. Five-axis computer numerical control (CNC) milling is the main parts machining method, while dynamics analysis has always been a research hotspot. The cutting conditions determined by the cutter axis, tool path, and workpiece geometry are complex and changeable, which has made dynamics research a major challenge. For this reason, this paper introduces the innovative idea of applying dimension reduction and mapping to the five-axis machining of curved surfaces, and proposes an efficient dynamics analysis model. To simplify the research object, the cutter position points along the tool path were discretized into inclined plane five-axis machining. The cutter dip angle and feed deflection angle were used to define the spatial position relationship in five-axis machining. These were then taken as the new base variables to construct an abstract two-dimensional space and establish the mapping relationship between the cutter position point and space point sets to further simplify the dimensions of the research object. Based on the in-cut cutting edge solved by the space limitation method, the dynamics of the inclined plane five-axis machining unit were studied, and the results were uniformly stored in the abstract space to produce a database. Finally, the prediction of the milling force and vibration state along the tool path became a data extraction process that significantly improved efficiency. Two experiments were also conducted which proved the accuracy and efficiency of the proposed dynamics analysis model. This study has great potential for the online synchronization of intelligent machining of large surfaces.