In FlexiSTAT, knowledge was developed to understand how the turning tools have to be moved and how the process parameters have to be set in order to achieve optimal simultaneous three axis turning machining. For this purpose, several models were developed to predict the uncut chip geometry, the process forces, the chip flow, the surface quality and the tool wear development in simultaneous three axis turning. Based on these models, basic process design rules were deduced for a first, semi-optimal process design. Also, a systematical method was developed which can be used in a subsequent step to further optimize the already existing tool path. As a result, it is possible to gradually design simultaneous three axis turning processes for arbitrary workpieces and for each individual machining case in an optimal way. The developments were also integrated into the developed CAM module, making the knowledge accessible for inexperienced SME end users as well.
Models, rules and methods to design stepwise simultaneous three axis turning processes in an optimal way