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Recently, the development of aerospace and automobile industries has brought new technological challenges, related to the growing
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complexity of products and the new geometry of the models. High speed milling with a 5-axis milling machine has been widely used for 3D
sculptured surface parts.9573
When turbine blades are machined by a 5-axis milling, their thin and cantilever shape causes vibrations, deflections and twists. Therefore,
the surface roughness and the waviness of the workpiece are not good.
In this paper, the effects of cutter orientation and the lead/tilt angle used to machine turbine blades with a 5-axis high speed ball end-milling
were investigated to improve geometric accuracy and surface integrity. The experiments were performed using a lead/tilt angle of 158 to the
workpiece with four cutter directions such as horizontal outward, horizontal inward, vertical outward, and vertical inward directions.
Workpiece deflection, surface roughness and the machined surface were all measured with various cutter orientations such as cutting
directions, and lead/tilt angle. The results show that the best cutting strategy for machining turbine blades with a 5-axis milling is horizontal
inward direction with a tilt angle.
# 2002 Published by Elsevier Science B.V.
Keywords: High speed milling; 5-Axis milling; Lead/tilt angle; Cutter orientation1. Introduction
Recently, there have been many studies of high speed
milling with regard to the high precision and the efficient
cutting in the aerospace, automobile, electronics, and semi-
conductor manufacturing industries.
High speed machining was suggested by Carl J. Salomon
[1] in 1924 to increase accuracy, lower costs and save
machining time. It has a possibility that reduce the material
removal volume per tooth at the high cutting speed as
compared to conventional cutting. Therefore, it is able to
do the high precision machining. On the other hand, it is
possible to have highly efficient manufacturing by using a
high feed rate and a material removal rate [2,3].
These days, the complex components of high dimension
accuracy have been required. However, it is impossible to
produce very precise products using the conventional 3-axis
milling. So, the importance of 5-axis milling has increased,
because of obtaining the high dimension accuracy by means
of the one set-up machining. Also, it is possible to carry out
side cutting, because the worker can change the inclined
angle of a tool. Consequently, the surface roughness is better
than that of a product produced by 3-axis milling. 5-Axis
milling has been employed to produce a wide range of
turbine blades, impellers, tire moulds and screws.
Several studies of 5-axis milling have been performed by
various authors. Rao et al. [4] showed both the avoidance of
gouging and the selection of an effective cutter profile for an
optimal choice of the feed direction for 5-axis milling.
Baptista and Antune Simoes [5] suggested that surface
roughness was improved with the inclined milling in the
feed direction. Tonshoff and Hernandez-Camacho [6] found
that the optimal inclined angle was 158 in ball end-milling of
block materials. This paper evaluates machinability based
on various cutter orientations such as cutting directions, and
*
Corresponding author. Present address: High Speed Machining System
Lab, ERC/NSDM, Pusan National University, Changjun-dong San 30,
Pusan 609-735, South Korea. Tel.: þ82-51-510-3092;
fax: þ82-51-514-2982.
E-mail address: machine1004@hanmail.net (T.-S. Lim).machine (MIKRON UCP-710). The maximum revolution
and feed rate of the machine are 42,000 rpm and 30 m/min,
respectively.
Table 1 shows the cutting conditions in this experiment.
All cutter orientations adopt a climb and dry cutting. In order
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