Tool orientation planning for five-axis CNC machining of open 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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Study on general analytical method for CNC machining the free-form surfaces

Journal of Materials Processing Technology ◽

10.1016/j.jmatprotec.2004.11.009 ◽

2005 ◽

Vol 168 (3) ◽

pp. 408-413 ◽

Cited By ~ 6

Author(s):

Eing-Jer Wei ◽

Ming-Chang Lin

Keyword(s):

Analytical Method ◽

Cnc Machining ◽

Free Form ◽

Free Form Surfaces

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Application of Convex Hull for Tool Interference Avoidance in 5-Axis CNC Machining

Volume 1: Design for Manufacturing Conference ◽

10.1115/96-detc/dfm-1294 ◽

1996 ◽

Author(s):

Yuan-Shin Lee ◽

Tien-Chien Chang

Keyword(s):

Convex Hull ◽

Tool Path ◽

Correction Method ◽

Nc Machining ◽

Cnc Machining ◽

Free Form ◽

Interference Avoidance ◽

Tool Interference ◽

Free Form Surface ◽

Free Form Surfaces

Abstract In this paper, a methodology of applying convex hull property in solving the tool interference problem is presented for 5-axis NC machining of free-form surfaces. Instead of exhausted point-by-point checking for possible tool interference, a quick checking can be done by using the convex hull constructed from the control polygon of free-form surface modeling. Global tool interference in 5-axis NC machining is detected using the convex hull of the free-form surface. A correction method for removing tool interference has also been developed to generate correct tool path for 5-axis NC machining. The inter-surface tool interference can be avoided by using the developed technique.

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Optimal feed rate control for multi-axis CNC machining of free form surfaces

Chinese Journal of Mechanical Engineering ◽

10.3901/cjme.2000.03.171 ◽

2000 ◽

Vol 13 (03) ◽

pp. 171

Author(s):

Yong Zhan

Keyword(s):

Rate Control ◽

Feed Rate ◽

Cnc Machining ◽

Free Form ◽

Optimal Feed ◽

Free Form Surfaces

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Adaptive Tool Path Planning Strategy for 5-Axis CNC Machining of Free Form Surfaces

Volume 2: Processes; Materials ◽

10.1115/msec2019-2737 ◽

2019 ◽

Cited By ~ 1

Author(s):

Hrishikesh Mane ◽

S. S. Pande

Keyword(s):

Tool Path ◽

Cnc Machining ◽

Memory Storage ◽

Free Form ◽

Cnc Machine ◽

Planning Strategy ◽

Part Quality ◽

Tool Paths ◽

Path Topology ◽

Free Form Surfaces

Abstract This paper presents a curvature based adaptive iso-parametric strategy for the efficient machining of free form surfaces on 5-axis CNC machine using the flat end mill tool. One iso-parametric boundary of the surface is selected as the initial tool path. Set of cutter contact (CC) points are chosen adaptively on the initial tool path considering desired profile tolerance. Adjacent iso-parametric tool paths are computed adaptively based on the scallop height constraint unlike the traditional iso-parametric approach. The path topology is post-processed to generate the part program for 5-axis CNC machine in ISO format. The system was rigorously tested for various case studies by comparing the results with the traditional 5-axis iso-parametric tool path strategy, iso-scallop strategy and iso-planar strategy of a commercial software. Our system was found to generate efficient tool paths in terms of part quality, productivity and memory storage compared to the conventional strategies.

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