Simulation of Five-Axes Milling Processes - Approaches and Applications

Zabel, A.1, a

Institut für Spanende Fertigung, Universität Dortmund, Baroper Str. 301, 44227 Dortmund



The paper describes some recent developments in modelling and simulation of five-axes milling processes. Two different modelling approaches are presented (CSG and multi-dexel). Special emphasize is taken on their computational complexity, determining the efficiency of the approaches. After the descriptions of the simulation approaches are given, some applications which are based on the described modelling techniques are discussed. Here the calculation of process forces is based on the CSG-modelling approach and it can be used for the prediction of chatter as well as for the modelling of the resulting workpiece surfaces. In the following a simulation based approach the prediction of tool wear and for the automatic generation of NC-paths for five axes milling are subsequently focused. Both are based on the multi-dexel model. The first approach is working on a semi-empiric wear model which was constructed with the help of the Design-of-Experiments (DoE) method from statistics while the second uses evolutionary algorithms to calculate and optimize NC-paths for five-axes milling.


Simulation, Fünfachsfräsen, Verschleißmodellierung, NC-Bahnoptimierung


Journal of Manufacturing Engineering, (2006) 6, S. 39-48