Five-Axis Part Machining With Three-Axis CNC Machine and Indexing Table

1998 ◽  
Vol 120 (1) ◽  
pp. 120-128 ◽  
Author(s):  
Suk-Hwan Suh ◽  
Jung-Jae Lee
Keyword(s):  
Tool Path ◽  
Solution Procedure ◽  
Algebraic Solution ◽  
Cnc Machine ◽  
Tool Paths ◽  
Path Computation ◽  
Part Surface ◽  
Five Axis ◽  
Surface Decomposition ◽  
Index Table

In this paper, we develop a versatile CAM method by which five axis machining can be effectively carried out with a three-axis CNC machine together with a rotary-tilt type indexing table. In this method, the part surface is divided into a set of subareas, and each subarea is machined by the virtually oriented tool whose orientation is provided via the index table. The key goal in developing our solution algorithm has been to minimizing the number of part setups (i.e., angle changes in the indexing table) and the surface ridges where multiple tool paths join. A robust algebraic solution procedure for achieving these practical criteria is presented, including the details of surface decomposition, tool path computation, and the interface of the index table. Since the developed method enables utilization of existing machines (equipped with three-axis control) for five-axis machining, the results are practically meaningful, especially for small to medium industries.

Study of The Tool Path Generation Method of an Ultra-Precision Spherical Complex Surface Based on a Five-Axis Machine Tool

2021 ◽  
Author(s):  
Tianji Xing ◽  
Xuesen Zhao ◽  
Zhipeng Cui ◽  
Rongkai Tan ◽  
Tao Sun
Keyword(s):  
Surface Roughness ◽  
Tool Path ◽  
Spherical Surface ◽  
Tool Path Generation ◽  
Path Generation ◽  
Tool Paths ◽  
Spherical Surfaces ◽  
Spherical Complex ◽  
Ultra Precision ◽  
Five Axis

Abstract The improvement of ultra-precision machining technology has significantly boosted the demand for the surface quality and surface accuracy of the workpieces to be machined. However, the geometric shapes of workpiece surfaces cannot be adequately manufactured with simple plane, cylindrical, or spherical surfaces because of their different applications in various fields. In this research, a method was proposed to generate tool paths for the machining of complex spherical surfaces based on an ultra-precise five-axis turning and milling machine with a C-Y-Z-X-B structure. Through the proposed tool path generation method, ultra-precise complex spherical surface machining was achieved. First, the complex spherical surface model was modeled and calculated, and then it was combined with the designed model to generate the tool path. Then the tool paths were generated with a numerically controlled (NC) program. Based on an ultra-precision three-coordinate measuring instrument and a white light interferometer, the machining accuracy of a workpiece surface was characterized, and t[1]he effectiveness of the provided tool path generation method was verified. The surface roughness of the machined workpiece was less than 90 nm. Furthermore, the surface roughness within the spherical region appeared to be less than 30 nm. The presented tool path generation method in this research produced ultra-precision spherical complex surfaces. The method could be applied to complex spherical surfaces with other characteristics.

A Voxel Model-Based Process-Planning Method for Five-Axis Machining of Complicated Parts

2020 ◽  
Vol 20 (4) ◽  
Author(s):  
Yamin Li ◽  
Kai Tang ◽  
Long Zeng
Keyword(s):  
Process Planning ◽  
Planning Method ◽  
Dynamic Problems ◽  
Tool Paths ◽  
New Process ◽  
Part Surface ◽  
Voxel Model ◽  
Voxel Representation ◽  
Complex Features ◽  
Five Axis

Abstract This paper presents a new process planning method for five-axis machining, which is particularly suitable for parts with complex features or weak structures. First, we represent the in-process workpiece as a voxel model. Facilitated by the voxel representation, a scalar field called subtraction field is then established between the blank surface and the part surface, whose value at any voxel identifies its removal sequence. This subtraction field helps identify a sequence of intermediate machining layers, which are always accessible to the tool and are free of self-intersection and the layer redundancy problem as suffered, respectively, by the traditional offset layering method and the morphing method. Iso-planar collision-free five-axis tool paths are then determined on the interface surfaces of these machining layers. In addition, to mitigate the deformation of the in-process workpiece and avoid potential dynamic problems such as chattering, we also propose a new machining strategy of alternating between the roughing and finishing operations, which is able to achieve a much higher stiffness of the in-process workpiece. Ample experiments in both computer simulation and physical cutting are performed, and the experimental results convincingly confirm the advantages of our method.

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

2019 ◽  
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.

Optimal Tool Orientation for Five-Axis Tool-End Machining by Swept Envelope Approach

2004 ◽  
Author(s):  
John C. J. Chiou ◽  
Yuan-Shin Lee
Keyword(s):  
Tool Path ◽  
Tool Orientation ◽  
Error Sources ◽  
Part Geometry ◽  
Machining Errors ◽  
Nc Simulation ◽  
Part Surface ◽  
Tool Motion ◽  
Five Axis ◽  
Cutting Direction

This paper presents a swept envelope approach to determining the optimal tool orientation for five-axis tool-end machining. The swept profile of the cutter is determined based on the tool motion. By analyzing the swept profile against the part geometry, four types of machining errors (local gouge, side gouge, rear gouge, and global collision) are identified. The tool orientation is then corrected to avoid such errors. The cutter’s swept envelope is further constructed by integrating the intermediate swept profiles, and can be applied to NC simulation and verification. This paper presents the explicit solution for the swept profile of a general cutter in five-axis tool-end machining. The relation of the swept profile, the part geometry, the tool motion, and the machining errors is developed. Therefore, the error sources can be detected early and prevented during tool path planning. The analytical results indicate that the optimal tool orientation occurs when the curvature of the cutter’s swept profile matches with the curvature of the local part surface. In addition, the optimal cutting direction generally follows the minimum curvature direction. Computer illustrations and example demonstrations are shown in this paper. The results reveal the developed method can accurately determine the optimal tool orientation and efficiently avoid machining errors for five-axis tool-end machining.

Path Planning for Motion Control of Hexapod Machines

2001 ◽  
Author(s):  
Zhiming Ji ◽  
Zhenqun Li
Keyword(s):  
Path Planning ◽  
Machine Tools ◽  
Tool Path ◽  
Local Planning ◽  
Tool Path Planning ◽  
Tool Paths ◽  
Condition Optimization ◽  
Planning Methods ◽  
Tool Motion ◽  
Five Axis

Abstract The dramatic departure in structure of the hexapod machine tools from the traditional five-axis machines leads to the question: can the planning and control methods for the traditional CNC machines be used for the hexapod machine tools? We studied several tool motion characteristics, such as Jocabian matrices, path tracking errors and the extra degree of freedom (e-DOF), and found that the traditional five-axis planning methods cannot take into consideration of the kinematics performance variation and the e-DOF in a hexapod. A kinematics-based tool path planning scheme for the hexapods is therefore proposed. It combines the traditional tool path planning with the kinematic condition optimization. The optimization is a two-step process. First a high accuracy zone of the workspace is identified globally for the placement of the part. Then a set of 5-DOF tool paths is generated and extended to a set of 6-DOF tool paths based on the local planning of e-DOF. Finally the relationship between the e-DOF and the stiffness of the Hexapods, another factor in the use of e-DOF, are discussed.

Development of a Virtual Controller Integrating Virtual and Physical CNC

2006 ◽  
Vol 505-507 ◽  
pp. 631-636 ◽  
Author(s):  
Yung Chou Kao ◽  
Hong Ying Chen ◽  
Y.C. Chen
Keyword(s):  
High Speed ◽  
Tool Path ◽  
Three Dimensional ◽  
Visual Basic ◽  
Cnc Machine ◽  
Geometry Model ◽  
International Exposition ◽  
Five Axis ◽  
Cnc Controller ◽  
Self Learning

This paper describes the development of a virtual CNC controller. Controller is the major driver for a CNC machine. Similarly, virtual controller is the key driving component for a virtual CNC, which is a three-dimensional digitized physical CNC. A virtual CNC can exist in every PC serving as the complementary safer counterpart in lecturing and learning the hand on operation of expensive machinery such as five-axis milling machine, high speed CNC and mill-turn because the virtual CNC will not break. Virtual reality environment provided by EON studio software has been adopted in establishing the interactivity of a virtual CNC based on the geometry model constructed in off-the-shelf CAD software. Visual Basic was used in implementing the graphical user interface to operate the virtual CNC through the developed virtual controller. The virtual controller is in charge of (1) parsing user’s NC codes, (2) simulating the tool path of the parsed NC codes, and (3)driving the virtual CNC according to the tool path. The developed virtual CNC controller has been successfully applied in implementing virtual CNCs based on two physical three-axis CNC machines and has also been demonstrated in an international exposition successfully. The virtual controller can enable the virtual CNC in facilitating lecturing, tutoring, self-learning, and reducing the chances of accidental breakdown of precious CNC equipment.

Generation of Optimal Tool-Paths for Five-Axis Finish Milling of Free-Form Surfaces

2012 ◽  
Vol 500 ◽  
pp. 440-446
Author(s):  
Lin Geng ◽  
Yun Feng Zhang
Keyword(s):  
Genetic Algorithm ◽  
Tool Path ◽  
Free Form ◽  
Machining Efficiency ◽  
Interference Avoidance ◽  
Tool Paths ◽  
Modified Genetic Algorithm ◽  
Novel Method ◽  
Five Axis ◽  
Free Form Surfaces

In this paper, a novel method is proposed to generate optimal 5-axis finish tool-paths regarding joint movements and machining efficiency. A modified genetic algorithm is used to search for the optimal posture sequence along a tool-path while interference avoidance and surface finish quality act as constraints. Case studies are then provided to prove the effectiveness of the algorithm.

A Benchmark Comparison of CAD 5-Axis Machining Packages

2004 ◽  
Author(s):  
Zhenyu Cheng ◽  
Robert Cheatham ◽  
Jianguo Wang ◽  
C. Greg Jensen ◽  
Yifan Chen ◽  
...  
Keyword(s):  
Surface Finish ◽  
Tool Path ◽  
Computation Time ◽  
Machining Efficiency ◽  
End Mill ◽  
Cad Systems ◽  
Path Computation ◽  
Density Surface ◽  
Five Axis

In this paper, parts from Ford GT were machined based on tool path created using Curvature Matched Machining and three other popular CAD systems. Five-axis flat end mill methods are used as the baseline of comparison. The performance of these CAD packages was compared using the benchmark of tool path density, surface finish, and post-machining finishing time. Results show that CM2 has advantage over today’s leading CAM capability in terms of both machining efficiency and tool path computation time.

A New Architecture of Tool Path Generation for Five-Axis Control Machining

2005 ◽  
Vol 291-292 ◽  
pp. 501-506 ◽  
Author(s):  
K. Nakamoto ◽  
K. Shirase ◽  
Akifumi Morishita ◽  
E. Arai ◽  
T. Moriwaki
Keyword(s):  
Machine Tool ◽  
Real Time ◽  
Manufacturing Systems ◽  
Tool Path ◽  
Cutting Parameters ◽  
Tool Paths ◽  
Nc Program ◽  
Digital Copy ◽  
Copy Milling ◽  
Five Axis

NC machine tools, which are widely employed in manufacturing systems, are basically driven by NC programs. However, it requires extensive amount of time and efforts to generate high quality tool paths before a machining operation. An NC program for five-axis control machining is more difficult to generate because the motion of machine tool is more complicated. In this paper, a new architecture is proposed to autonomously control the machine tool without an NC program for more rapid and flexible machining. A technique called digital copy milling is developed to generate the tool paths in real time based on the principle of copy milling. It means that the cutting parameters can be adaptively controlled in order to maintain stable cutting process and to avoid the cutting troubles. In the experimental verification, the improved digital copy milling system for five-axis control milling successfully detected and avoided tool collision in real-time.

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