NC Machining Simulation for Design and Manufacturing of Integral Impeller Based on UG NX 12.0

Various advantages derive from applying 5-axis machines instead of using 3-axis machines. Main advantage is high flexibility in tool coordination in space and reduction of assembling time for complicated wok piece, multiple barricade occurs during set-up process for the further procedures by using only 3-axis machining. Eliminating the extra fixture time maximum parts can be assembled in single or two set-ups by using 5-axis machining.

Integral impeller is absolute example that can be precisely designed and manufactured with high degree of flexibility in tool orientation by using CAD/CAM systems. Impellers are widely use in multiple industries such as aerospace, automobiles and biomedical industries and ship building industries. large amount of methods are proposed through researchers for impeller manufacturing. Most manufacturer use Master CAM, CATIA, UG NX, VERICUT, SolidWorks, Power mill for manufacturing of impellers. To overcome the issue of time consumption this paper explains useful strategies of machining impeller by integrating depth cut distance, change in feed rate and tool diameter by using 3 and 5-axis machining strategy simultaneously. Ball end rough milling and finishing test are conducted on aluminum workpiece. As production coast is directly linked with machining time, which is directly related with feed rate, and machining tool and machining method. This paper also describes validation analysis and brief comparison of time lag with the simulation. 3-axis machining strategy undermine because of its high ability of rigidity as compared to full five axis.Through this study, overall machining time can be reduced to 53.9 percent respectively and the cutting force model for 5axis ball end cutting force prediction is also illustrated with a carbide cutting tool.