Tool positioning method for achieving double-point contact in flank milling of a concave surface with a barrel cutter

2017 ◽  
Vol 93 (5-8) ◽  
pp. 1791-1807 ◽  
Author(s):  
Zhu Yu ◽  
Chen Zhi-Tong ◽  
Zhang Yun ◽  
Ning Tao
2009 ◽  
Vol 407-408 ◽  
pp. 292-297
Author(s):  
Dan Wang ◽  
Wu Yi Chen ◽  
Tian Li ◽  
Ru Feng Xu

A flank milling tool positioning method using a barrel cutter is proposed. An offset point is used as the first anchor point. Two rotary angles of the barrel cutter are adjusted to find the optimized tool position with the largest machining strip width. The result tool position calculated using the proposed method is gouge-free because the local interference avoidance method is integrated inside the tool positioning procedure. Error distribution beneath the barrel cutter is well estimated by virtual of the instant envelope curve of the cutter. The envelope curve is discretized into points. The distances between these points and the model surface are the machining errors beneath the cutter. The employment of the envelope curve also largely reduces the computational load of the algorithm. Finally, numerical implementation and simulation are performed to validate the feasibility of the method.


Physica ◽  
1972 ◽  
Vol 59 (1) ◽  
pp. 155-160 ◽  
Author(s):  
A.Th.A.M. de Waele ◽  
C.P.M. Vergouwen ◽  
A.A.J. Matsinger ◽  
R. de Bruyn Ouboter

2018 ◽  
Vol 97 (1-4) ◽  
pp. 279-295 ◽  
Author(s):  
Ravinder Kumar Duvedi ◽  
Sanjeev Bedi ◽  
Stephen Mann

Nature ◽  
2005 ◽  
Vol 437 (7057) ◽  
pp. 393-395 ◽  
Author(s):  
F. B. Mancoff ◽  
N. D. Rizzo ◽  
B. N. Engel ◽  
S. Tehrani

2003 ◽  
Vol 91 (15) ◽  
Author(s):  
Eun-Ah Kim ◽  
Eduardo Fradkin

2017 ◽  
Vol 4 (3) ◽  
pp. 203-217 ◽  
Author(s):  
Ke Xu ◽  
Jiarui Wang ◽  
Chih-Hsing Chu ◽  
Kai Tang

Abstract Five-axis flank milling has been commonly used in the manufacturing of complex workpieces because of its greater productivity than that of three-axis or five-axis end milling. The advantage of this milling operation largely depends on effective cutter location planning. The finished surface sometimes suffers from large geometrical errors induced by improper tool positioning, due to the non-developability of most ruled surfaces in industrial applications. In addition, a slender flank-milling cutter may be deflected when subjected to large cutting forces during the machining process, further degrading the surface quality or even breaking the cutter. This paper proposes a novel tool path planning scheme to address those problems. A simple but effective algorithm is developed to adaptively allocate a series of cutter locations over the design surface with each one being confined within an angular rotation range. The allocation result satisfies a given constraint of geometrical errors on the finished surface, which consists of the tool positioning errors at each cutter location and the sweeping errors between consecutive ones. In addition, a feed rate scheduling algorithm is proposed to maximize the machining efficiency subject to the cutting force constraint and the kinematical constraints of a specific machine configuration. Simulation and experimental tests are conducted to validate the effectiveness of the proposed algorithms. Both the machining efficiency and finish surface quality are greatly improved compared with conventional cutter locations. Highlights Tool position is bounded with respect to the geometrical machining error. Cutting force and kinematics during five-axis flank milling process are analyzed. An incremental adaptive flank milling tool path generation algorithm is proposed. Feed rate is smoothly assigned respecting cutting force and kinematic constraints.


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