ORIGINAL ARTICLE Machining strategy development and parameter selection in 5-axis milling based on process simulations Lütfi Taner Tunç 1 & Omer Mehmet Ozkirimli 1 & Erhan Budak 1 Received: 4 July 2015 /Accepted: 20 October 2015 # Springer-Verlag London 2015 Abstract In modern machining applications, with the devel- opments in computer-aided manufacturing (CAM) technolo- gy, predictive modeling of milling operations has gained mo- mentum. However, there is still a big gap between CAM tech- nology and process modeling which limits its use in machin- ing strategy development and parameter selection. In this pa- per, an approach is proposed for the use of process models and simulation tools in this direction. Cutting force and stability simulations are used in identification of feasible regions of cutting parameters and comparison of machining strategies for productivity. Cutting force simulation throughout a toolpath is performed through extended Z-mapping approach, where a previously developed generalized cutting force model is utilized. Stability diagrams are generated in frequency do- main. Dynamic programming (DP) approach is adapted for machining strategy comparison, which takes into account sev- eral constraint curves such as chatter stability, cutting torque, spindle power, tool deflection, and surface roughness. The proposed approach was applied on a case study to demonstrate the use of process models in machining strategy and parameter selection in 5-axis milling. Keywords Process modeling . Multi-axis milling . Cutting mechanics . Chatter stability . Machining strategy 1 Introduction Improper selection of machining strategy and parameters may lead to significant loss in overall productivity. In practice, machining data handbooks or tool manufacturer’ s catalogues used for parameter selection are generally set conservatively, which may be improved by trial and error methods requiring excessive test time. In selection of machining strategies, the default methods offered by the computer-aided design (CAD)/ computer-aided manufacturing (CAM) software are used without much assistance as general solutions. Process models can be used to predict the mechanics and dynamics of cutting process to support suitable selection of cutting conditions for increased productivity [1–3]. In the last decades, several pro- cess models have been developed for simulation of 3-axis and 5-axis milling operations. As this paper focuses on machining strategy selection based on process simulations, the studies on machining strategy development and parameter selection are reviewed in this section. In a recent CIRP keynote paper, Altintas et al. [3] reviewed process models for simulation of machining operations, where it is emphasized that the process models developed for simulation of mechanics and dynamics of metal cutting need to be integrated with geometric models. The use of process models for parameter selection is also demonstrated. In the literature, several authors dealt with selection of ma- chining strategies in terms of selection of toolpath pattern, where cutting forces, tool deflections, and maximum feed rate maps are utilized to decide feed direction and select the best toolpath pattern. In one of the early studies, Lim and Menq [4] proposed an algorithm for selection of best local cutting direc- tions, where various cutting directions at each cutter location is compared with respect to cutting forces. The maximum feed rate map is also generated using cutting force simulations. Later, Lazoglu et al. [5] applied this approach on 5-axis * Erhan Budak ebudak@sabanciuniv.edu 1 Manufacturing Research Lab, Sabanci University, Istanbul, Turkey Int J Adv Manuf Technol DOI 10.1007/s00170-015-8001-6