Simulation of the NC Milling Process for the Prediction and Prevention of Chatter

2013 ◽  
pp. 19-25 ◽  
Author(s):  
S. Odendahl ◽  
R. Joliet ◽  
E. Ungemach ◽  
A. Zabel ◽  
P. Kersting ◽  
...  
Keyword(s):  
Milling Process ◽  
Prediction And Prevention ◽  
Nc Milling

Cutter Engagement Feature Extraction by Using Dexel Representation Solid Model

2012 ◽  
Vol 523-524 ◽  
pp. 420-432 ◽  
Author(s):  
Masatomo Inui ◽  
Nobuyuki Umezu
Keyword(s):  
Feature Extraction ◽  
Cutting Force ◽  
Metal Cutting ◽  
Experimental System ◽  
Simulation Method ◽  
Milling Process ◽  
Solid Model ◽  
Small Motion ◽  
Nc Milling ◽  
Feature Based

Computer simulation of the cutting force change in a milling process is important for realizing more stable, precise, and efficient metal cutting. In the latest cutting force simulation method, a cutter engagement feature representing a contact area between the milling cutter and the workpiece must be extracted for each small motion of the cutter. In this paper, a new algorithm is proposed for computing a cutter engagement feature based on the dexel representation of the workpiece. Most prior studies compute the feature based on the cutter removal volume of the workpiece. Differently from them, our technology to propose computes the cutter engagement feature based on the contact analysis between the cutter and dexels representing the workpiece shape. An experimental system is implemented and some computational experiments are performed. Our system can achieve the total cutter engagement feature extraction of a complex 3-axis NC milling process in a few minutes.

Automatic Prototyping of Complex Geometries for Conceptual Design

1990 ◽  
Author(s):  
J. S. M. Vergeest ◽  
J. J. Broek ◽  
J. W. H. Tangelder
Keyword(s):  
Conceptual Design ◽  
Milling Process ◽  
Interference Avoidance ◽  
Physical Constraints ◽  
Mechanical Parts ◽  
Shape Models ◽  
Solid Models ◽  
Graphical Visualization ◽  
Model Extension ◽  
Nc Milling

Abstract The significance of materialized prototypes from CAD generated mechanical parts has been recognized since more than a decade. Despite the ever increasing quality and speed of graphical visualization methods, solid 3D hard copies from designs remain essential for certain stages in the creation process. Especially during the phase of conceptual geometric design, when alternative shape proposals must be quickly judged, automatic, fast and inexpensive production of replica is of importance. However, for such a kind of prototyping in conjunction with CAD, traditional methods based on CAM and NC technology turn out not adequate. To support conceptual design, several extensions and optimizations, mainly in the software area, need to be effected. In this paper an autonomous NC-milling process generator TLCOR is presented. It evaluates and analyzes surface/solid models based on NURBS, determines the physical constraints of the 3D milling devices (represented in a technical database) and finally produces an ISO-standard control statement sequence. The system selects the appropriate machining method (parametric and/or geometric algorithms) and tools, and breaks up the process into different stages of non-planar path planning with interference avoidance. The user will never be confronted with any aspect concerning the NC. The designer only needs to express his or her wish to obtain a milled copy of the actual CAD model. Extension of TLCOR to shape models defined neutrally (STEP/PDES based) and to multi-axis and robot milling is in progress.

A Comparison of Two Methods for Geometric Milling Simulation Accelerated by GPU

2012 ◽  
Author(s):  
Masatomo Inui ◽  
Nobuyuki Umezu ◽  
Yuuki Shinozuka
Keyword(s):  
Cutting Force ◽  
Milling Process ◽  
Small Motion ◽  
Milling Simulation ◽  
Milling Operation ◽  
Cutter Path ◽  
Nc Milling ◽  
Depth Buffer ◽  
Swept Volume ◽  
The Cost

For detecting potential problems of a cutter path, cutting force simulation in the NC milling process is necessary prior to actual machining. A milling operation is geometrically equivalent to a Boolean subtraction of the swept volume of a cutter moving along a path from a solid model representing the stock shape. In order to precisely estimate the cutting force, the subtraction operation must be executed for every small motion of the cutter. The performance and the cost of the polygon rendering LSI called GPU are dramatically improved these days. By using GPU, the required time for critical computations in the geometric milling simulation can be drastically reduced. In this paper, the computation speed of two known GPU accelerated milling simulation methods, which are the depth buffer based method and the parallel processing based method with CUDA language, are compared. Computational experiments with complex milling simulations show that the implementation with CUDA is several times faster than the depth buffer based method when the cutter motion in the simulation process is sufficiently small.

Analysis on the NC Milling Machining Precision and the Error

2014 ◽  
Vol 926-930 ◽  
pp. 1214-1217
Author(s):  
Bo Tang
Keyword(s):  
Process Design ◽  
Process Analysis ◽  
Milling Process ◽  
Numerical Control ◽  
Machining Process ◽  
Cnc Milling ◽  
Machining Precision ◽  
Cnc Milling Machine ◽  
Process Route ◽  
Nc Milling

the numerical control milling process design is on the basis of ordinary milling process design, combining with the characteristics of CNC milling machine, give full play to its advantages. CNC milling process design is the key to reasonable arrangement of process route, to coordinate the relationship between the CNC milling process and other process, determine the content and steps of NC milling process make the necessary preparations for programming. NC milling machining process analysis is related to the effectiveness and success or failure, is one of the important preparations before programming. This article will mainly for NC milling machining precision and machining error analysis and research.

Research on the Simulation of NC Milling Program Based on VERICUT Oriented to the Five-Axis Micro-Milling System

2014 ◽  
Vol 599-601 ◽  
pp. 417-421
Author(s):  
Xiang Hui Zhang ◽  
Zhan Wen Sun ◽  
Jin Zhao ◽  
Hua Dong Yu
Keyword(s):  
Simulation Model ◽  
Milling Process ◽  
Micro Milling ◽  
Virtual Machining ◽  
Milling Simulation ◽  
Motion Structure ◽  
Processing Program ◽  
Nc Milling ◽  
Processing Module ◽  
Five Axis

In order to verify the correctness of the NC processing program which is generated by the post processing module of the Independently developed 5-axis micro-milling system, this article analyze the motion structure and obtained the topology relation between the feed shafts of the micro-milling system, established the milling simulation model of the micro-milling system by the VERICUT—the Virtual machining simulation platform. The milling process of an example part with a typical ellipsoid structure has been simulated by the milling simulation model and the correctness of the NC processing program and coordinate transforming relation have been verified by the simulation result.

A Methodology of Off-Line Optimization for NC Milling Process

2006 ◽  
pp. 1-5
Author(s):  
Y.X. Yao ◽  
Chang Qing Liu ◽  
J.G. Li ◽  
H.J. Jing ◽  
S.D. Chen
Keyword(s):  
Milling Process ◽  
Nc Milling

On CNC Machining and Part Program Preprocessing Based on STEP-NC

2004 ◽  
Vol 471-472 ◽  
pp. 326-329
Author(s):  
Cheng Rui Zhang ◽  
Ri Liang Liu
Keyword(s):  
Milling Process ◽  
Cnc Machining ◽  
Numerical Control ◽  
Shop Floor ◽  
Prototype System ◽  
Numerical Control Machining ◽  
Nc Programming ◽  
Part Program ◽  
Nc Milling ◽  
Nc Data

STEP-NC is a new CAM/CNC interface and an extension of STEP into numerical control machining. It has been partly formed into draft international standard (ISO 14649) and is expected to replace ISO 6983 in the near future. In the first section of this paper, the STEP-NC data model is analyzed and those parts that are relevant to NC milling process are abstracted. Then issues involved in NC part machining based on STEP-NC paradigm are discussed including NC programming and the machine control. Based on the analysis, a prototype system is outlined and partly developed with libraries and software tools in ST-Developer environment to interpret the part program into internal data format and to assist the shop floor level planning. Finally the user interface of this system is introduced.

A Methodology of Off-Line Optimization for NC Milling Process

2006 ◽  
Vol 315-316 ◽  
pp. 1-5 ◽  
Author(s):  
Ying Xue Yao ◽  
Chang Qing Liu ◽  
Jian Guang Li ◽  
H.J. Jing ◽  
S.D. Chen
Keyword(s):  
End Milling ◽  
Cutting Parameters ◽  
Optimization Method ◽  
Milling Process ◽  
Machining Process ◽  
Machining Time ◽  
Cutting Power ◽  
Nc Program ◽  
Nc Milling ◽  
Control Technologies

Traditional adaptive control technologies in machining process optimization are limited in applications because they depend much on sensors, controllers and other hardware. An off-line optimization method for end milling process with constant cutting power is presented. On taking advantage of virtual machining which simulates milling process, acquires cutting parameters and predicts cutting forces, method taking constant cutting power as an objective is discussed to optimize feed rates and cutting speeds. Based on optimal result, the feed rates and spindle revolutions in NC program are re-scheduled. Controlled milling experiments show that machining time is reduced and machining stability is improved by using the optimized NC program.

Fast and Smooth NC Milling Animation Using Partial Redrawing Technique

2001 ◽  
Author(s):  
Masatomo Inui ◽  
Makoto Takano
Keyword(s):  
Experimental System ◽  
Milling Process ◽  
Potential Problems ◽  
Cutter Path ◽  
Nc Milling

Abstract Animation display of the NC milling process is helpful for detecting potential problems of a cutter path prior to actual machining. In the milling animation, machined shape of the workpiece is repeatedly computed and displayed after every short motion of the cutter. A single cutter motion usually removes very small portion of the workpiece, therefore most part of two successive pictures in the animation becomes the same. Based on this characteristic of the pictures, the authors develop “partial redrawing technique” for fast and smooth animation of the NC milling process. This method efficiently generates a new picture of the workpiece by properly modifying a limited part of the latest picture in the screen. The picture area to modify is determined based on the removed shape of the workpiece. An experimental system is implemented and some animations of complex milling processes are demonstrated.

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