Simulation and experimental

of 5- axis milling

Mohd Firdaus bin Abdullah

GS24740

Supervisor : Dr. Mohd Khairol Anuar Mohd Ariffin

Seminar (Research Proposal) SPS 5903

Introduction
Milling
one of material removal process

Milling machine available-

3-axis
4-axis
5-axis
Introduction
 3-axis milling machine

 Axis X,Y,Z
Introduction
 4-axis milling machine

 Axis X,Y,Z, A
Introduction
 5-axis milling machine

 Axis X,Y,Z,A,C
Introduction

 Overview of lead and tilt angle

 Fixed coordinate system, MCS

 Process coordinate system, FCN, consisting of

feed(F), cross-feed(C) and surface normal(N) axes

Introduction
5-axis milling machine
-popular in aerospace industries, automotive
and die/mould and machining of scultured
surfaces (E. Ozturk 2007)
- Widely used due to capability of complex
surface machining. (E-budak 2009)
Introduction
 Scope of study
This study is focusing on finding the effects of
the change of the lead and tilt angle in 5-axis
milling that affects tool deflection, surface
roughness, and tool wear.
Introduction
 Objective

The overall objective is to study the effect of

the change of tilt and lead angle in 5-axis
milling by using modeling, simulation and
experimental method which focus on:
i. Deflection of the cutting tool
Introduction
 Expected results
i. Determine the relation of the tilt and lead
angle with the deflection of the cutting tool,
tool wear and surface roughness
ii. Define the effects of the tool wear to the
surface roughness
iii. Optimization the milling parameters in 5-
axis milling
Literature Review
In 5-axis milling – cutting force deflect the
cutting tool which result to form error of the
machining part. (G.M Kim 2003)

Effects of lead and tilt angle are not known

very well as others parameters. (Erdem
Ozturk 2009)
Methodology
START

Preliminary study

Milling operation condition

Modeling

Simulation

Experimental

Results & Discussion

Recommendation

END
Methodology
 Milling
operation condition
Condition of the different lead and tilt angle in
5-axis milling operation

 Analytical Modeling
The milling condition modeled analytically to
proceed to simulation stage.
i) Modeling of deflection