Abstract
In the five-axis stable milling of thin-walled blades, significant variations in surface micro-ripple morphology have been observed under different tool rake and tilt angle combinations, even when cutting parameters are within the chatter-free zone. This phenomenon suggests that tool attitude regulates the formation of residual ripples through a dynamic mechanism rather than simple geometric projection. To reveal the physical nature of this process, this paper proposes a surface topography modeling method that couples the forced vibration response with tool attitude. First, a two-dimensional dynamic model considering periodic cutting force excitation is established to solve for the forced vibration responses in the feed and normal directions. These vibration perturbations are then superimposed onto the ideal tool path. Subsequently, a three-dimensional surface topography simulation model is constructed, incorporating coordinate transformations to predict the microscopic residual ripple structure under various attitude combinations. Simulation results based on two typical experimental attitudes (30°/−45° and 15°/−15°) show strong agreement with measured data in terms of residual height and corrugation patterns. The study reveals that the 30°/−45° attitude effectively suppresses normal vibration and improves surface quality. This work provides a theoretical basis and a predictive tool for tool attitude optimization and micro-quality control in complex multi-axis machining processes.
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