Process optimization and typical application based on geometrical analysis and response surface method for high-speed five-axis ball-end milling operation

High-speed five-axis ball-end milling operations could achieve high efficiency, good surface integrity, and high accuracy in machining of complex components for many manufacture fields. This work concentrated on the machined surface properties and cutting performance produced by the multi-axis ball-end milling process in order to enhance the high performance application of this technology. Variations of the potential tool–workpiece contact zone; the cutting section area, and perimeter corresponding to eight types of tool posture; and the influence of the different tool postures on the machining characteristics were analyzed by geometrical modeling method. The tool postures with negative tilt angles, positive lead angles, or compound inclination angles with negative tilt angle and positive lead angle are beneficial to improve cutting effects with larger effective cutting speed. Discussions on the response analysis and optimization of the machined surface roughness, surface hardness, and the average and maximum cutting forces were conducted under up milling condition. Furthermore, the multi-objective coupling optimization for process performance and surface integrity and typical application in practical machining were carried out for high-speed multi-axis ball-end milling, and the optimization plans are validated by detection and analysis of the machined surface. The research results would promote the high performance application of the high-speed multi-axis ball-end milling operation.