Five-axis flank milling error model of a face gear considering the tool tip dynamics.

The five-axis flank milling process of sculptured surfaces is an intricate process involving time-varying and nonlinear characteristics under the multiphysics coupling effect. The milling force during the process is an important factor that influences the machining accuracy of sculptured surfaces. Face gears, as parts with sculptured surfaces, are widely employed in the aerospace and machinery manufacturing industries. To realize the high-precision manufacturing of face gears with a universal milling machine, this study proposes a five-axis flank milling method for face gears. In addition, based on the tangent plane approximation algorithm and the Receptance Coupling Substructure Analysis (RCSA) method, the milling force and the tool tip vibration during the face gear machining process are investigated. Finally, a five-axis flank milling force model and a face gear surface machining error model are established considering the interaction between the milling force and the process system. [ABSTRACT FROM AUTHOR]