A Review in Capabilities and Challenges of 5-Axis CNC Milling Machine Tool Operations

To produce sophisticated parts with free form surfaces such as turbine blades, airfoils, impellers and aircraft components, 5-axis CNC machine tools are used. Cutting Toolpath and cutter orientation in 5-axis CNC machine tool operations are analyzed and optimized to improve performance and quality of produced parts. Sculptured surface cutting operations utilizing 5-axis CNC machine tools are analyzed and modified to increase quality of part production. Cutting forces prediction and analysis are presented to provide ability of cutting force and cutting tool monitoring system along machining paths. To create and analyze actual machined parts in virtual environments, virtual machining systems are developed. Machining operations of flexible thin-walled parts using 5-axis CNC machine tools are analyzed to increase dimensional accuracy of produced parts. Tool wear prediction in 5-axis milling operations is presented to analyze and modify performance of cutting tools in milling operations. To decrease cutting tool failure in milling operations, cutting tool temperature estimation is proposed. Rotary axis of 5-axis CNC machine tools are analyzed and modified to increase precision of rotary axis during machining operations of free form surface. To increase quality of machined surfaces using 5-axis CNC machine tools, advanced machining strategies for smooth cutting tool paths are developed. Optimized cutting tool paths for minimum energy consumption are studied in order to minimize energy consumption in machining operations. Capabilities and challenges of 5-axis CNC machine tool operations is reviewed in the study in order to develop the process of part production. Thus, innovative concepts and approaches of research works in developing 5-axis CNC machine tool operations can be presented to enhance accuracy as well as efficiency in process of part manufacturing.