Comparison of Non-conventional Intelligent Algorithms for Optimizing Sculptured Surface CNC Tool Paths

2018 ◽  
pp. 349-370
Author(s):  
Nikolaos A. Fountas ◽  
Nikolaos M. Vaxevanidis ◽  
Constantinos I. Stergiou ◽  
Redha Benhadj-Djilali
Keyword(s):  
Sculptured Surface ◽  
Intelligent Algorithms ◽  
Tool Paths

Efficient NC Tool Path Planning Based on the Subdivision of Sculptured Surface

2014 ◽  
Vol 635-637 ◽  
pp. 497-501
Author(s):  
Li Min ◽  
Biao Bai ◽  
Yu Hou Wu ◽  
De Hong Zhao
Keyword(s):  
Path Planning ◽  
Tool Path ◽  
High Efficiency ◽  
Parametric Method ◽  
Sculptured Surface ◽  
Machining Efficiency ◽  
Tool Path Planning ◽  
Tool Paths ◽  
Surface Subdivision ◽  
Planning Methods

In this paper, we have presented a method to generate efficient NC tool paths based on the surface subdivision. The main objective is to achieve high efficiency in the machining of sculptured surface. The NC machining efficiency can be improved by segmenting the whole surface into distinct areas according to the characters of sculptured surface and by using different size mills and different tool path planning methods to machine the areas. The iso-parametric method and large mills are used in the curvature changing little areas. While the iso-scallop method and small mills are used in curvatures changing large areas. This can make full use of tool path generation methods and mills, which improve the machining efficiency of sculpture effectively.

An Intelligent Approach to Multiple Cutters of Maximum Sizes for Three-Axis Milling of Sculptured Surface Parts

2008 ◽  
Vol 131 (1) ◽  
Author(s):  
Zezhong C. Chen ◽  
Gang Liu
Keyword(s):  
Tool Path ◽  
Generic Model ◽  
Interference Detection ◽  
Sculptured Surface ◽  
Surface Machining ◽  
Tool Paths ◽  
Sculptured Surface Machining ◽  
Cutter Selection ◽  
Intelligent Approach ◽  
Local Gouging

Due to their complex geometries, sculptured surface parts should be machined with multiple cutters of optimal sizes for high quality and productivity. Current methods of determining cutter sizes, however, are conservative and inefficient; their repeating process includes subjective cutter selection, intensive tool-path generation, and time-consuming gouging-and-interference detection in simulation. Our research proposes a new intelligent approach to multiple standard cutters of maximum sizes for three-axis sculptured surface machining. An innovative generic model of maximum allowable cutters in three-axis surface milling is built to eliminate any cutter causing local gouging and global interference. After the optimum standard cutters are automatically selected, their accessible regions can be identified, and the corresponding tool-paths can be generated, respectively. This approach is practical and effective in the process planning for three-axis milling of sculptured surface parts.

Generating Cartesian NC tool paths for sculptured surface manufacture

1994 ◽  
Vol 26 (2) ◽  
pp. 359-367 ◽  
Author(s):  
Kwangsoo Kim ◽  
Byungchul Ko
Keyword(s):  
Sculptured Surface ◽  
Tool Paths

A Generic, Geometric Approach to Accurate Machining-Error Predictions for 3-Axis CNC Milling of Sculptured Surface Parts: Part II — Applications and Analysis

2006 ◽  
Author(s):  
Zezhong C. Chen ◽  
Wei Cai
Keyword(s):  
Tool Path ◽  
Geometric Approach ◽  
Sculptured Surface ◽  
Cnc Milling ◽  
Sculptured Surfaces ◽  
Machining Error ◽  
Tool Paths ◽  
Machining Errors ◽  
Tool Surface ◽  
Cam Software

As sculptured surfaces are widely used in mechanical design, machining sculptured surface parts accurately is highly demanded in industry; however, it is quite challenging to meet their demand. Due to the geometric complexity of these surfaces, the tool-surface geometric mismatch always causes machining errors when the tool cuts along the tool paths. To prevent surface gouging, where the machining error is greater than the part tolerance, state-of-the-art CAM software usually determines cutter contact (CC) points on the tool paths first, and then simulates the machining to check the errors caused by this tool-surface mismatch. If surface gouging occurs, the CC points are adjusted using the CAM software. But this established method is quite time consuming and sometimes ineffective. To overcome these problems, a new system, based on the accurate predictions of machining errors, is proposed in this research paper for the optimization of CC points on the tool paths. First, two established CC point generation methods, the chordal deviation method and the circular arc approximation method, are introduced; and their limitations are addressed. Second, a sensitivity study of the machining errors with respect to the cutting tools is conducted. Then a system implementing the generic, geometric approach to accurate machining-error predictions is proposed to optimize CC points on the tool paths. Finally, this CC point optimization system is applied to two practical parts to demonstrate its advantages over the two established methods. This proposed work provides a profound understanding of the machining errors caused by the tool-surface mismatch and contributes to tool path planning for 3-axis CNC milling of sculptured surface parts.

A New Principle of CNC Tool Path Planning for Three-Axis Sculptured Part Machining—A Steepest-Ascending Tool Path

2004 ◽  
Vol 126 (3) ◽  
pp. 515-523 ◽  
Author(s):  
Zezhong C. Chen ◽  
Geoffrey W. Vickers ◽  
Zuomin Dong
Keyword(s):  
Path Planning ◽  
Tool Path ◽  
Tool Path Generation ◽  
Surface Shape ◽  
Sculptured Surface ◽  
Machining Efficiency ◽  
Path Generation ◽  
Tool Path Planning ◽  
Tool Paths ◽  
Sculptured Parts

Three-axis CNC milling is often used to machine sculptured parts. Due to the complex surface shape of these parts, well-planned tool paths can significantly increase the machining efficiency. In this work a new principle of CNC tool path planning for 3-axis sculptured surface machining is proposed. Generic formula to calculate the steepest tangent direction of a sculptured surface is derived, and the algorithm of the steepest-ascending tool path generation is introduced. A single steepest-ascending tool path has been verified to be more efficient than a single tool path of any other type. The relationship between machining efficiency and three key variables, tool feed direction, cutter shape, and surface shape, is revealed. The newly introduced principle is used in planning tool paths of a sculptured surface to demonstrate the advantages of the steepest-ascending tool paths. This new tool path scheme is further integrated into the more advanced steepest-directed and iso-cusped (SDIC) tool path generation technique. Applications of the new tool path principle and the SDIC tool paths to the machining of sculptured parts are demonstrated.

A Swept Ellipse Offsetting Approach for Three-Axis Sculptured Surface Tool Path Generation

2004 ◽  
Author(s):  
Peter Jang ◽  
James A. Stori
Keyword(s):  
High Speed ◽  
Tool Path ◽  
Contact Point ◽  
Tool Path Generation ◽  
Sculptured Surface ◽  
Path Generation ◽  
Surface Machining ◽  
Tool Paths ◽  
Sculptured Surface Machining ◽  
Processing Techniques

This paper presents a new offsetting approach for tool path generation in three-axis sculptured surface machining. The approach generates tool paths with scallop, curvature, and force characteristics which make them suitable for high speed machining. An ellipse in the parametric space is used to approximate the intersection between the ball-end mill and the scallop surface for any cutter contact point on the surface. The envelope formed by these swept ellipses of varying dimension and orientation creates a constant scallop curve which is used to generate offset paths. The offset is developed incrementally, utilizing post-processing techniques to eliminate high-curvature regions in the trajectory. The offsetting approach can generate continuous spiraling trajectories which offer the benefit of minimal tool retractions. Results are shown for spiraling paths generated from both convex and non-convex boundaries.

scholarly journals Intelligent Optimization for Sculptured Surface CNC Tool-paths

Procedia CIRP ◽  
2016 ◽  
Vol 55 ◽  
pp. 140-145
Author(s):  
N.A. Fountas ◽  
C.I. Stergiou ◽  
V.D. Majstorović ◽  
N.M. Vaxevanidis
Keyword(s):  
Sculptured Surface ◽  
Intelligent Optimization ◽  
Tool Paths

scholarly journals An integrated framework for optimizing sculptured surface CNC tool paths based on direct software object evaluation and viral intelligence

2017 ◽  
Vol 30 (4) ◽  
pp. 1581-1599 ◽  
Author(s):  
N. A. Fountas ◽  
R. Benhadj-Djilali ◽  
C. I. Stergiou ◽  
N. M. Vaxevanidis
Keyword(s):  
Sculptured Surface ◽  
Integrated Framework ◽  
Tool Paths ◽  
Software Object

scholarly journals Precision Sculptured Surface CNC Machining Using Cutter Location Data

2016 ◽  
Vol 686 ◽  
pp. 224-233
Author(s):  
Nikolaos A. Fountas ◽  
Nikolaos M. Vaxevanidis ◽  
Constantinos I. Stergiou ◽  
Redha Benhadj-Djilali
Keyword(s):  
Tool Path ◽  
Low Cost ◽  
Cnc Machining ◽  
Sculptured Surface ◽  
Sculptured Surfaces ◽  
Rough Machining ◽  
Machining Error ◽  
Location Data ◽  
Tool Paths ◽  
Cutter Location Data

Industrial parts with sculptured surfaces are typically, manufactured with the use of CNC machining technology and CAM software to generate surface tool paths. To assess tool paths computed for 3-and 5-axis machining, the machining error is evaluated in advance referring to the parameter controlling the linearization of high-order curves, as well as the scallop yielded as a function of radial cutting engagement parameter. The two parameters responsible for the machining error are modeled and corresponding cutter location data for tool paths are utilized to compare actual trajectories with theoretical curves on a sculptured surface assessing thus the deviation when virtual tools are employed to maintain low cost; whilst ensuring high precision cutting. This operation is supported by applying a flexible automation code capable of computing the tool path; extracting its CL data; importing them to the CAD part and finally projecting them onto the part’s surface. For a given tolerance, heights from projected instances are computed for tool paths created by changing the parameters under a cutting strategy, towards the identification of the optimum tool path. To represent a global solution rough machining is also discussed prior to finish machining where the new proposals are mainly applied.

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