A novel approach to modeling of multi-axis plunge milling and its application on the simulation of complex part plunging

Open blisks are important parts of aero-engines and plunging is a common and efficient method of rough machining open blisks. However, the research on the simulation of open blisk’s four-axis plunging is far from mature. In this paper, an in-process model of four-axis plunging is established to represent the part’s geometry in the process of plunging. Then, a method of evaluating the residual and overcut of the material is proposed. The minimum required bottom edge length is calculated based on the in-process model, and an algorithm to determine the critical plunging depth is invented. The simulation reveals that the method proposed is valid and can be used directly in industry.