scholarly journals Numerical implementation of drop spin and tilt method for five-axis tool positioning for tensor product surfaces

2021 ◽  
Author(s):  
Sandeep Kumar Sharma ◽  
Ravinder Kumar Duvedi ◽  
Sanjeev Bedi ◽  
Stephen Mann
Keyword(s):  
Tensor Product ◽  
Numerical Implementation ◽  
Tool Positioning ◽  
Five Axis

scholarly journals Numerical Implementation of Drop Spin and Tilt Method For Five-Axis Tool Positioning For Tensor Product Surfaces

2021 ◽  
Author(s):  
Sandeep Kumar Sharma ◽  
Ravinder Kumar Duvedi ◽  
Sanjeev Bedi ◽  
Stephen Mann
Keyword(s):  
Tensor Product ◽  
Strip Width ◽  
Numerical Implementation ◽  
Symbolic Algebra ◽  
Tool Positioning ◽  
Contact Points ◽  
Uniform Spacing ◽  
Machining Strip Width ◽  
Quadratic Surface ◽  
Five Axis

Abstract This paper presents an extension of multi point machining technique, called the Drop Spin and Tilt (DST) method, that spins the tool on two axes, allowing for the generation of multiple contact points at varying distances around the first point of contact. The multiple DST second points of contact were used to manually generate a toolpath with uniform spacing between the two points of contact. The original DST method used a symbolic algebra package to position the tool on a bi-quadratic surface; our extension is a numer- ical solution that allows positioning a toroidal tool on a tensor product Bezier surface. Further, we investigate the spread of possible second points of contact as the tool is spun around these two axes, demonstrating the feasability of using the method to control the machining strip width.

Drop and tilt method of five-axis tool positioning for tensor product surfaces

2017 ◽  
Vol 93 (1-4) ◽  
pp. 617-622 ◽  
Author(s):  
Ravinder Kumar Duvedi ◽  
Sanjeev Bedi ◽  
Stephen Mann
Keyword(s):  
Tensor Product ◽  
Tool Positioning ◽  
Five Axis

scholarly journals Collision-free tool orientation optimization in five-axis machining of bladed disk

2015 ◽  
Vol 2 (4) ◽  
pp. 197-205 ◽  
Author(s):  
Li Chen ◽  
Ke Xu ◽  
Kai Tang
Keyword(s):  
Tool Path ◽  
Poor Quality ◽  
Reference Plane ◽  
Jet Engines ◽  
Tool Orientation ◽  
Worst Case ◽  
Machine Vibration ◽  
Tool Positioning ◽  
Bladed Disk ◽  
Five Axis

Abstract Bladed disk (BLISK) is a vital part in jet engines with a complicated shape which is exclusively machined on a five-axis machine and requires high accuracy of machining. Poor quality of tool orientation (e.g., false tool positioning and unsmooth tool orientation transition) during the five-axis machining may cause collision and machine vibration, which will debase the machining quality and in the worst case sabotage the BLISK. This paper presents a reference plane based algorithm to generate a set of smoothly aligned tool orientations along a tool path. The proposed method guarantees that no collision would occur anywhere along the tool path, and the overall smoothness is globally optimized. A preliminary simulation verification of the proposed algorithm is conducted on a BLISK model and the tool orientation generated is found to be stable, smooth, and well-formed.

scholarly journals Cutting force and machine kinematics constrained cutter location planning for five-axis flank milling of ruled surfaces

2017 ◽  
Vol 4 (3) ◽  
pp. 203-217 ◽  
Author(s):  
Ke Xu ◽  
Jiarui Wang ◽  
Chih-Hsing Chu ◽  
Kai Tang
Keyword(s):  
Cutting Force ◽  
Surface Quality ◽  
Feed Rate ◽  
Tool Path ◽  
Flank Milling ◽  
Machining Efficiency ◽  
Location Planning ◽  
Tool Positioning ◽  
Finished Surface ◽  
Five Axis

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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