Generalized cutting loads decomposition model of five-axis serial machine tools based on the screw theory

There are large volume of existing literatures focused on cutting force modeling, but so far only few research has been reported on cutting loads decomposition model to calculate cutting loads components acted on five axes of the machine, which, however, directly affect five-axis tracking accuracy. To this end, a generalized cutting loads decomposition model of five-axis serial machine tools is proposed, which provides a mathematical basis to evaluate the cutting loads components. A cutting loads decomposition model is first developed based on kinematics and virtual work analysis, then a generalized cutting loads decomposition model is established by differentiating the forward kinematics model based on the screw theory. Kinematic factors that affect the cutting load components on translational and rotary axes are also analyzed, which provides a guidance to optimize the workpiece setup location to reduce the cutting loads components acted on rotary axes. Experiments and simulations on a table-tilting five-axis machine tool verify the effectiveness of the proposed model.