Geometric error compensation of five-axis ball-end milling based on tool orientation optimization and tool path smoothing

2020 ◽  
Vol 108 (5-6) ◽  
pp. 1737-1749
Author(s):  
Guoqiang Fu ◽  
Jing Liu ◽  
Yongjian Rao ◽  
Hongli Gao ◽  
Caijiang Lu ◽  
...  
Keyword(s):  
Error Compensation ◽  
Tool Path ◽  
End Milling ◽  
Geometric Error ◽  
Tool Orientation ◽  
Ball End Milling ◽  
Path Smoothing ◽  
Five Axis ◽  
Tool Orientation Optimization ◽  
Orientation Optimization

Tool Orientation Planning in Milling With Process Dynamic Constraints: A Minimax Optimization Approach

2018 ◽  
Vol 140 (11) ◽  
Author(s):  
Tao Huang ◽  
Xiao-Ming Zhang ◽  
Jürgen Leopold ◽  
Han Ding
Keyword(s):  
Tool Path ◽  
End Milling ◽  
Tool Path Generation ◽  
Optimization Approach ◽  
Path Generation ◽  
Tool Orientation ◽  
Minimax Optimization ◽  
Ball End Milling ◽  
Dynamic Constraints ◽  
Five Axis

In five-axis milling process, the tool path generated by a commercial software seldom takes the dynamics of the machining process into account. The neglect of process dynamics may lead to milling chatter, which causes overcut, quick tool wear, etc., and thus damages workpiece surface and shortens tool life. This motivates us to consider dynamic constraints in the tool path generation. Tool orientation variations in five-axis ball-end milling influence chatter stability and surface location error (SLE) due to the varying tool-workpiece immersion area and cutting force, which inversely provides us a feasible and flexible way to suppress chatter and SLE. However, tool orientations adjustment for suppression of chatter and SLE may cause drastic changes of the tool orientations and affects surface quality. The challenge is to strike a balance between the smooth tool orientations and suppression of chatter and SLE. To overcome the challenge, this paper presents a minimax optimization approach for planning tool orientations. The optimization objective is to obtain smooth tool orientations, by minimizing the maximum variation of the rotational angles between adjacent cutter locations, with constraints of chatter-free and SLE threshold. A dedicated designed ball-end milling experiment is conducted to validate the proposed approach. The work provides new insight into the tool path generation for ball-end milling of sculpture surface; also it would be helpful to decision-making for process parameters optimization in practical complex parts milling operations at shop floor.

Geometric error compensation for five-axis ball-end milling by considering machined surface textures

2018 ◽  
Vol 99 (5-8) ◽  
pp. 1235-1248 ◽  
Author(s):  
Guoqiang Fu ◽  
Tengda Gu ◽  
Hongli Gao ◽  
Yu’an Jin ◽  
Xiaolei Deng
Keyword(s):  
Error Compensation ◽  
End Milling ◽  
Geometric Error ◽  
Machined Surface ◽  
Surface Textures ◽  
Ball End Milling ◽  
Five Axis

scholarly journals Minimizing Flute Engagement to Adjust Tool Orientation for Reducing Surface Errors in Five-Axis Ball End Milling Operations

2020 ◽  
Vol 143 (2) ◽  
Author(s):  
M. Habibi ◽  
Z. M. Kilic ◽  
Y. Altintas
Keyword(s):  
Optimization Problem ◽  
Tool Path ◽  
End Milling ◽  
Contact Point ◽  
Geometrical Approach ◽  
Tool Orientation ◽  
Ball End Milling ◽  
Surface Errors ◽  
Five Axis ◽  
Path Modification

Abstract Surface errors due to force-induced tool and workpiece deflections are one of the major errors in multi-axis machining of parts especially with thin-walled structures. Dominant approaches to reduce these surface errors are re-machining the part, feed scheduling, and tool path modification. These methods are time consuming and computationally costly, and they rely on experimental data which is used in cutting force and deflection predictions. The present paper introduces a pure geometrical approach to reduce surface errors drastically by minimizing the engagement lengths of flutes’ cutting edges when a point on the flute’s cutting edge is in contact with the design surface. The total engagement length of the flutes’ cutting edges when one of them generates a contact point on the workpiece surface is formulated and considered as the minimization objective function of an optimization problem. Tilt and lead angles, which define the tool orientation, are the design variables of the optimization problem subjected to constraints based on the geometrical requirements of the ball end milling process. The optimization problem uses the nominal tool path to generate an optimal tool path with adjusted tool orientations. The presented method is computationally inexpensive and does not need any experimentally calibrated coefficients to predict cutting forces because of the pure geometrical nature of the approach. The method is experimentally validated through five-axis ball end milling experiments in which more than 90% surface error reduction is achieved.

A Real-Time C3 Continuous Tool Path Smoothing and Interpolation Algorithm for Five-Axis Machine Tools

2020 ◽  
Vol 142 (4) ◽  
Author(s):  
Qin Hu ◽  
Youping Chen ◽  
Xiaoliang Jin ◽  
Jixiang Yang
Keyword(s):  
Coordinate System ◽  
Real Time ◽  
Machine Tools ◽  
Tool Path ◽  
Maximum Deviation ◽  
Interpolation Algorithm ◽  
Tool Orientation ◽  
Path Smoothing ◽  
Tip Position ◽  
Five Axis

Abstract Local corner smoothing method is commonly adopted to smooth linear (G01) tool path segments in computer numerical control (CNC) machining to realize continuous motion at transition corners. However, because of the highly non-linear relation between the arc-length and the spline parameter, and the challenge to synchronize the tool tip position and tool orientation, real-time and high-order continuous five-axis tool path smoothing and interpolation algorithms have not been well studied. This paper proposes a real-time C3 continuous corner smoothing and interpolation algorithm for five-axis machine tools. The transition corners of the tool tip position and tool orientation are analytically smoothed in the workpiece coordinate system (WCS) and the machine coordinate system (MCS) by C3 continuous PH splines, respectively. The maximum deviation errors of the smoothed tool tip position and the tool orientation are both constrained in the WCS. An analytical synchronization algorithm is developed to guarantee the motion variance of the smoothed tool orientation related to the tool tip displacement is also C3 continuous. The corresponding real-time interpolation method is developed with a continuous and peak-constrained jerk. Simulation results verify that the maximum deviation errors caused by the tool path smoothing algorithm are constrained, and continuous acceleration and jerk of each axis are achieved along the entire tool path. Comparisons demonstrate that the proposed algorithms achieve lower amplitude and variance of acceleration and jerk when compared with existing methods. Experiments show that the proposed five-axis corner smoothing and interpolation algorithms are serially executed in real-time with 0.5-ms cycle.

Form error compensation in ball-end milling of sculptured surface with z-level contouring tool path

2013 ◽  
Vol 67 (9-12) ◽  
pp. 2853-2861 ◽  
Author(s):  
Z. C. Wei ◽  
M. J. Wang ◽  
W. C. Tang ◽  
J. N. Zhu ◽  
G. C. Xia
Keyword(s):  
Error Compensation ◽  
Tool Path ◽  
End Milling ◽  
Sculptured Surface ◽  
Form Error ◽  
Ball End Milling

Cutter partition-based tool orientation optimization for gouge avoidance in five-axis machining

2017 ◽  
Vol 95 (5-8) ◽  
pp. 2041-2057 ◽  
Author(s):  
Xiyan Li ◽  
Chen-Han Lee ◽  
Pengcheng Hu ◽  
Yang Zhang ◽  
Fangzhao Yang
Keyword(s):  
Tool Orientation ◽  
Gouge Avoidance ◽  
Five Axis ◽  
Tool Orientation Optimization ◽  
Orientation Optimization

Evaluation of Surface Roughness in Five-Axis Ball-End Milling

2020 ◽  
pp. 21-31
Author(s):  
B.B. Ponomarev ◽  
S.H. Nguyen
Keyword(s):  
Surface Roughness ◽  
Tilt Angle ◽  
End Milling ◽  
Free Form ◽  
Tool Orientation ◽  
Ball End Milling ◽  
Lead Angle ◽  
Tool Tilt Angle ◽  
Five Axis ◽  
Free Form Surfaces

Unlike three-axis machining, five-axis machining allows the end tool or workpiece to be oriented at any angle relative to the machine axis OZ. It can be achieved by changing the values of the tool tilt angle and lead angle relative to the surface normal in the contact zone of the tool surface and the workpiece, taking into account the direction of the table feed. The article presents experimental results of analyzing the influences of tool orientation on transverse roughness during ball end milling using 2-flute and 4-flute 8 mm diameter mills. The analysis the arithmetic mean deviation of the assessed profile at various values of tool tilt angle and lead angle showed that the position of the tool point with a zero cutting speed significantly affects the surface quality. The results of the evaluation of the tool orientation influence on the surface roughness enable the selection of optimal tool orientation angles when developing control programs for end milling of free-form surfaces on five-axis CNC milling machines.

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