Virtual cutting to improve the product tolerances of 5 axes machine tools

The aim of this research is to predict the tolerance and surface finish of a machined product thanks to the study of the dynamic behavior of a 5 axes machine tool and to correct the toolpath and process parameters (i.e. feed) in order to meet the specifications. To reach this goal will be realized an approach to evaluate the dynamic stiffness of the machine, the forces during machining (both cutting and inertial forces) and the tool displacement. The analysis of the static and dynamic behavior of the machine will be predicted thanks to the development of a flexible multi-body model with special care to joints characterization. Some variables of the model will be characterized experimentally on the machine and will be conducted specific machining tests to validate the model. The paper reports also some preliminary results for a 3 axes milling machine.