Five-axis machining refers to machining a part of certain shape by a tool that can have arbitrary orientation and position in space. In this talk, some recent research results by the speaker in freeform surface five-axis machining are presented. Specifically, the following topics will be discussed:
(1) How to decide a setup on the five-axis machine table for a workpiece of complex geometry so that a minimum number of setups are required to machine the entire part, respecting all types of obstacles?
(2) Given the specification of the five-axis machine, how to place the workpiece on the machine’s table so the machining will consume the minimum amount of energy?
(3) How to generate a five-axis tool path that will strive to minimize either the total machining time or the total energy consumption while respecting the given kinematic and dynamic loading constraints of the given five-axis machine?
(4) Variable depth milling of thin-walled workpiece to improve both the machining efficiency and machining accuracy.
(5) Chattering-avoiding and tool-life prolonging milling process of a freeform surface.
In addition, recent major industrial projects in five-axis machining system development by the speaker will also be discussed.