Tool deflection and geometrical error compensation by tool path modification

2011 ◽  
Vol 51 (6) ◽  
pp. 439-449 ◽  
Author(s):  
Mohsen Habibi ◽  
Behrooz Arezoo ◽  
Mehrdad Vahebi Nojedeh
Keyword(s):  
Error Compensation ◽  
Tool Path ◽  
Tool Deflection ◽  
Geometrical Error ◽  
Path Modification ◽  
Tool Path Modification

A Tool Path Modification Approach to Cutting Engagement Regulation for the Improvement of Machining Accuracy in 2D Milling With a Straight End Mill

2007 ◽  
Vol 129 (6) ◽  
pp. 1069-1079 ◽  
Author(s):  
M. Sharif Uddin ◽  
Soichi Ibaraki ◽  
Atsushi Matsubara ◽  
Susumu Nishida ◽  
Yoshiaki Kakino
Keyword(s):  
Cutting Force ◽  
Case Studies ◽  
Tool Path ◽  
Free Form ◽  
Geometric Accuracy ◽  
End Mill ◽  
Workpiece Surface ◽  
Engagement Angle ◽  
Path Modification ◽  
Tool Path Modification

In two-dimensional (2D) free-form contour machining by using a straight (flat) end mill, conventional contour parallel paths offer varying cutting engagement with workpiece, which inevitably causes the variation in cutting loads on the tool, resulting in geometric inaccuracy of the machined workpiece surface. This paper presents an algorithm to generate a new offset tool path, such that the cutting engagement is regulated at a desired level over the finishing path. The key idea of the proposed algorithm is that the semi-finish path, the path prior to the finishing path, is modified such that the workpiece surface generated by the semi-finish path gives the desired engagement angle over the finishing path. The expectation with the proposed algorithm is that by regulating the cutting engagement angle along the tool path trajectory, the cutting force can be controlled at any desirable value, which will potentially reduce variation of tool deflection, thus improving geometric accuracy of machined workpiece. In this study, two case studies for 2D contiguous end milling operations with a straight end mill are shown to demonstrate the capability of the proposed algorithm for tool path modification to regulate the cutting engagement. Machining results obtained in both case studies reveal far reduced variation of cutting force, and thus, the improved geometric accuracy of the machined workpiece contour.

Off-line error compensation in corner milling process

2016 ◽  
Vol 232 (7) ◽  
pp. 1172-1181 ◽  
Author(s):  
Caixu Yue ◽  
Xianli Liu ◽  
Yunpeng Ding ◽  
Steven Y Liang
Keyword(s):  
Cutting Force ◽  
Error Compensation ◽  
Tool Path ◽  
Chip Thickness ◽  
Milling Process ◽  
Process Conditions ◽  
Force Model ◽  
Tool Deflection ◽  
Profile Error ◽  
Compensation Algorithm

Tool deflection induced by cutting force could result in dimensional inaccuracies or profile error in corner milling process. Error compensation has been proved to be an effective method to get accuracy component in milling process. This article presents a methodology to compensate profile errors by modifying tool path. The compensation effect strongly depends on accuracy of the cutting force model used. The mathematical expression of chip thickness is proposed based on the true track of cutting edge for corner milling process, which considers the effect of tool deflection. The deflection of tool is calculated by finite element method. Then, an off-line compensation algorithm for corner profile error is developed. Following the theoretical analysis, the effect of the error compensation algorithm is verified by experimental study. The outcome provides useful comprehension about selection of process conditions for corner milling process.

scholarly journals Machining Time Reduction by Tool Path Modification to Eliminate Air Cutting Motion for End Milling Operation

2020 ◽  
Vol 14 (3) ◽  
pp. 459-466 ◽  
Author(s):  
Isamu Nishida ◽  
◽  
Keiichi Shirase
Keyword(s):  
Tool Path ◽  
End Milling ◽  
Axial Direction ◽  
Contour Line ◽  
Product Model ◽  
Machining Time ◽  
High Productivity ◽  
Product Surface ◽  
Path Modification ◽  
Tool Path Modification

A method to uniquely calculate the tool path and to modify the tool path during air cutting motion to reduce the machining time is proposed. This study presents a contour line model, in which the product model is minutely divided on a plane along an axial direction, and the contour line of the cross-section of the product is superimposed. A method is then proposed to calculate the tool position according to the degree of interference between the product surface and the tool. Furthermore, this study proposes a technique to reduce the machining time by tool path modification during air cutting motion. This is determined by the geometric relationship between the product surface and the tool, and not based on cutting simulations. A cutting experiment was conducted to validate the effectiveness of the proposed method. Based on the results, it was confirmed that the difference in machining time between the tool path with modification and the tool path without modification was large. Moreover, the machining time was significantly reduced by the tool path modification. The results showed that the proposed method has good potential to perform customized manufacturing, and to realize both high productivity and reliability in machining operation.

Error correction technique for numerical control machine tools based on the simplex method

2021 ◽  
pp. 095440542110281
Author(s):  
Hongwei Liu ◽  
Rui Yang ◽  
Pingjiang Wang ◽  
Jihong Chen ◽  
Hua Xiang
Keyword(s):  
Machine Tool ◽  
Error Compensation ◽  
Simplex Method ◽  
Tool Path ◽  
Repeated Measurements ◽  
Numerical Control ◽  
Machining Accuracy ◽  
Correction Technique ◽  
Fluctuation Range ◽  
Nc Machine

The objective of this research is to develop a novel correction mechanism to reduce the fluctuation range of tools in numerical control (NC) machining. Error compensation is an effective method to improve the machining accuracy of a machine tool. If the difference between two adjacent compensation data is too large, the fluctuation range of the tool will increase, which will seriously affect the surface quality of the machined parts in mechanical machining. The methodology used in compensation data processing is a simplex method of linear programming. This method reduces the fluctuation range of the tool and optimizes the tool path. The important aspect of software error compensation is to modify the initial compensation data by using an iterative method, and then the corrected tool path data are converted into actual compensated NC codes by using a postprocessor, which is implemented on the compensation module to ensure a smooth running path of the tool. The generated, calibrated, and amended NC codes were immediately fed to the machine tool controller. This technique was verified by using repeated measurements. The results of the experiments demonstrate efficient compensation and significant improvement in the machining accuracy of the NC machine tool.

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