scholarly journals Surface Topography Prediction Model for Free-form Surface Milling under a Dynamic System Response

2021 ◽  
Vol 2044 (1) ◽  
pp. 012140
Author(s):  
Huiqun Chen ◽  
Fenpin Jin
2021 ◽  
Vol 2021 ◽  
pp. 1-18
Author(s):  
Zhaozhao Lei ◽  
Xiaojun Lin ◽  
Gang Wu ◽  
Luzhou Sun

In order to improve the machining quality and efficiency and optimize NC machining programming, based on the existing cutting force models for ball-end, a cutting force prediction model of free-form surface for ball-end was established. By analyzing the force of the system during the cutting process, we obtained the expression equation of the instantaneous undeformed chip thickness during the milling process and then determined the rule of the influence of the lead angle and the tilt angle on the instantaneous undeformed chip thickness. It was judged whether the cutter edge microelement is involved in cutting, and the algorithm flow chart is given. After that, the cutting force prediction model of free-form surface for ball-end and pseudocodes for cutting force prediction were given. MATLAB was used to simulate the prediction force model. Finally, through the comparative analysis experiment of the measured cutting force and the simulated cutting force, the experimental results are basically consistent with the theoretical prediction results, which proves that the model established in this paper can accurately predict the change of the cutting force of the ball-end cutter in the process of milling free-form surface, and the error of the cutting force prediction model established in this paper is reduced by 15% compared with the traditional cutting force prediction model.


2017 ◽  
Vol 98 (1-4) ◽  
pp. 151-163 ◽  
Author(s):  
Lin Yang ◽  
Shi Wu ◽  
Xianli Liu ◽  
Zhijing Liu ◽  
Meiwen Zhu ◽  
...  

2015 ◽  
Vol 51 (7) ◽  
pp. 5128-5144 ◽  
Author(s):  
Wei Si ◽  
Weimin Bao ◽  
Hoshin V. Gupta

2021 ◽  
Vol 28 (1) ◽  
pp. 113-118
Author(s):  
Bin Chen ◽  
Quanying Wu ◽  
Junliu Fan

Author(s):  
Tomonobu Suzuki ◽  
Koichi Morishige

Abstract This study aimed to improve the efficiency of free-form surface machining by using a five-axis controlled machine tool and a barrel tool. The barrel tool has cutting edges, with curvature smaller than the radius, increasing the pick feed width compared with a conventional ball end mill of the same tool radius. As a result, the machining efficiency can be improved; however, the cost of the barrel tool is high and difficult to reground. In this study, a method to obtain the cutting points that make the cusp height below the target value is proposed. Moreover, a method to improve the tool life by continuously and uniformly changing the contact point on the cutting edge is proposed. The usefulness of the developed method is confirmed through machining simulations.


Author(s):  
Yuan-Shin Lee ◽  
Tien-Chien Chang

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.


Author(s):  
P. A. van Elsas ◽  
J. S. M. Vergeest

Abstract Surface feature design is not well supported by contemporary free form surface modelers. For one type of surface feature, the displacement feature, it is shown that intuitive controls can be defined for its design. A method is described that, given a surface model, allows a designer to create and manipulate displacement features. The method uses numerically stable calculations, and feedback can be obtained within tenths of a second, allowing the designer to employ the different controls with unprecedented flexibility. The algorithm does not use refinement techniques, that generally lead to data explosion. The transition geometry, connecting a base surface to a displaced region, is found explicitly. Cross-boundary smoothness is dealt with automatically, leaving the designer to concentrate on the design, instead of having to deal with mathematical boundary conditions. Early test results indicate that interactive support is possible, thus making this a useful tool for conceptual shape design.


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