Analytical Modeling and Simulation of the Envelope Surface in Five-Axis Flank Milling With Cutter Runout

2012 ◽  
Vol 134 (2) ◽  
Author(s):  
Yuwen Sun ◽  
Qiang Guo
Keyword(s):  
Flank Milling ◽  
Error Prediction ◽  
Surface Model ◽  
Form Error ◽  
Cutter Runout ◽  
Machined Surface ◽  
Rotation Surface ◽  
Envelope Surface ◽  
Tool Positioning ◽  
Five Axis

The cutter runout effect has significant influence on the shape of the cutter swept surface and the machining surface quality. Due to the existence of cutter runout effect, the shape and position of envelope surface formed by each cutter edge are different from others. Hence, it is necessary to integrate the cutter runout effect and its resulting compound effects of all cutter edges into envelope surface modeling and form error prediction for five-axis milling. This paper establishes the envelope surface model considering cutter runout effect in five-axis flank milling based on the relative motion analysis of the cutter and part. In this model, the cutter runout is defined by three parameters, including inclination angle, location angle, and offset value, and the cutter runout effect is subsequently integrated into the model by using the cutter edge as the generatrix of cutter rotation surface. Then, the influence of each runout parameter on the shape of envelope surface formed by each cutter edge as well as the resulting form error in milling is investigated. Also, the compound effects of all cutter edges on the final resulting geometric errors of the machined surface are analyzed. Finally, simulations and machining experiment are conducted for a specific ruled surface, and the results validate the effectiveness and feasibility of proposed envelope surface model considering cutter runout effect. It is suitable to be used in tool positioning, tool installation adjustment, and forming error prediction in flank milling process with cutter runout.

Envelope Surface Modeling and Tool Path Optimization for Five-Axis Flank Milling Considering Cutter Runout

2014 ◽  
Vol 136 (4) ◽  
Author(s):  
Zhou-Long Li ◽  
Li-Min Zhu
Keyword(s):  
Distance Function ◽  
Tool Path ◽  
Surface Modeling ◽  
Path Optimization ◽  
Mixed Integer ◽  
Flank Milling ◽  
Cutter Runout ◽  
Tool Path Optimization ◽  
Envelope Surface ◽  
Five Axis

Cutter runout is a common and inevitable phenomenon impacting the geometry accuracy in the milling process. However, most of the works on tool path planning neglect the cutter runout effect. In this paper, a new approach is presented to integrate the cutter runout effect into envelope surface modeling and tool path optimization for five-axis flank milling with a conical cutter. Based on the geometry model of cutter runout which consists of cutter axis and cutter tilt, an analytic expression of cutter edge combined with four runout parameters is derived. Then the envelope surface formed by each cutter edge is constructed using the envelope theory of sphere congruence. Due to the cutter runout effect, the envelope surfaces formed by the cutter edges are different from each other, and the valid envelope surface is the combination of these envelope surfaces which contribute to the final machined surface. To measure the machining errors, the geometry deviations between the valid envelope surface and the design surface are calculated with the distance function. On the basis of the differential property of the distance function, tool path optimization considering cutter runout is modeled as a mixed-integer linear programming (MILP) problem, which can be solved by the branch-and-bound method. Finally, numerical examples are given to confirm the validity and efficiency of the proposed approach. The results show that the geometry errors induced by runout can be reduced significantly using the proposed method.

Surface form error prediction in five-axis flank milling of thin-walled parts

2018 ◽  
Vol 128 ◽  
pp. 21-32 ◽  
Author(s):  
Zhou-Long Li ◽  
Oguzhan Tuysuz ◽  
Li-Min Zhu ◽  
Yusuf Altintas
Keyword(s):  
Flank Milling ◽  
Error Prediction ◽  
Surface Form ◽  
Form Error ◽  
Thin Walled ◽  
Five Axis

Geometric deviation reduction method for interpolated toolpath in five-axis flank milling of the S-shaped test piece

2019 ◽  
Vol 234 (5) ◽  
pp. 910-919 ◽  
Author(s):  
Liping Wang ◽  
Weitao Li ◽  
Hao Si ◽  
Xing Yuan ◽  
Yuzhe Liu
Keyword(s):  
Test Piece ◽  
Reduction Method ◽  
Linear Interpolation ◽  
Machining Process ◽  
Flank Milling ◽  
Machined Surface ◽  
Location Data ◽  
Geometric Deviation ◽  
Five Axis ◽  
Cutter Location Data

Geometric deviation, defined as the distance between the designed surface and the machined surface, is an important component of machining errors in five-axis flank milling of the S-shaped test piece. Since the interpolated toolpath in practical machining process is the approximation of the theoretical toolpath, the geometric deviation caused by the interpolated toolpath appears. To overcome this problem, a novel geometric deviation reduction method is suggested in this study. First, the features of the S-shaped test piece are analyzed. Second, the theoretical toolpath is generated according to the designed surface and the cutter location data is obtained by discretizing the theoretical toolpath. The linear interpolation of the cutter location data is carried out to obtain the interpolated toolpath. Then, the geometric deviation is modeled by calculating the Hausdorff distance between the tool axis trajectory surface based on the interpolated toolpath and the offset surface of the designed surface. Finally, the geometric deviation is reduced by optimizing the cutter location data without inserting more cutter location points. The machining experiment is conducted to verify the effectiveness of the proposed method. The experimental results agree with the simulation results, and both of them indicate the geometric deviation on the machined surface reduces after optimization.

scholarly journals Prediction of machining accuracy based on geometric error estimation of tool rotation profile in five-axis multi-layer flank milling process

2020 ◽  
Vol 234 (11) ◽  
pp. 2160-2177
Author(s):  
Hangzhuo Yu ◽  
Lei Jiang ◽  
Jindong Wang ◽  
Shengfeng Qin ◽  
Guofu Ding
Keyword(s):  
Prediction Model ◽  
Great Influence ◽  
Milling Process ◽  
Geometric Error ◽  
Flank Milling ◽  
Machining Accuracy ◽  
Machined Surface ◽  
Contact Points ◽  
Five Axis ◽  
Tool Rotation

In five-axis multi-layer flank milling process, the geometric error of tool rotation profile caused by radial dimension error and setup error has great influence on the machining accuracy. In this work, a new comprehensive error prediction model considering the inter-layer interference caused by tool rotation profile error is established, which incorporates a pre-existing prediction model dealing with a variety of errors such as geometric errors of machine tool, workpiece locating errors, and spindle thermal deflection errors. First, a series of tool contact points on the tool swept surface in each single layer without overlapping with others are calculated. Second, the position of the tool contact points on the overlapped layers is updated based on the detection and calculation of inter-layer interferences. Third, all evaluated tool contact points on the final machined surface are available for completing the accuracy prediction of the machined surface. A machining experiment has been carried out to validate this prediction model and the results show the model is effective.

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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