Synthesis of Cutting Tool Placement, Orientation and Motion Based on Surface Analysis

2000 ◽  
Author(s):  
C. G. Jensen ◽  
J. K. Hill ◽  
K. A. White
Keyword(s):  
Tool Path ◽  
Cutting Tool ◽  
A Priori ◽  
Cutting Tools ◽  
Detection Algorithm ◽  
Detection Methods ◽  
Machined Surface ◽  
Mathematical Basis ◽  
Five Axis ◽  
Verification Techniques

Abstract Engineers and designers use a wide variety of curve and surface formulations to describe products. The process of producing the physical shape of these products has remained essentially unchanged for many years. Traditionally, the process of finish surface machining has been error prone and inefficient due in large part to the mathematical basis used to control the positioning, orientation and movement of cutting tools in five-axis machining centers. This paper presents swept silhouette curvature matching algorithms for positioning and orienting a cutter such that tool and surface curvatures match. Formulations are given for both flat and filleted end mill cutters. The benefits of curvature matching are: reduction of local machining errors, reduction or elimination of grinding of the finished machined surface, and the improvement of machine tool efficiency. Examples are given that compare curvature matching to traditional machining methods. The paper concludes by discussing current research into a priori gouge detection methods based on intersection contact between the cutting tool and the design surface or the lower tolerance-bound offset surface to the design surface. An a priori gouge detection algorithm is necessary for the development of optimal tool motion and the reduction of time spent in tool path editing and verification. Techniques involving collinear normals, Bézier clipping, triangulation, normal intersection and swept volumes are suggested as techniques for examining the positional and translational tool gouge problem.

Study on Path Planning of Involute Tooth Surface Milling With General Cutting Tool

2019 ◽  
Author(s):  
Zhaoyao Shi ◽  
Zhipeng Feng ◽  
Peng Wang
Keyword(s):  
Tool Path ◽  
Cutting Tool ◽  
Market Competition ◽  
Cutting Tools ◽  
Difficult Problem ◽  
Milling Process ◽  
Tooth Surface ◽  
Involute Gear ◽  
Accurate Position ◽  
Cutting Path

Abstract Milling involute tooth surface with universal cutting tool overcomes the difficult problem of customizing tool for nonstandard gear machining. It is difficult for gear manufacturers to gain an advantage in market competition because of the long cycle of customized cutting tools. In this paper, the milling path of involute tooth surface by a general cutting tool is studied, and how to obtain the uniform surface roughness of involute tooth surface and the cutting path scheme of cutting tool is discussed. The key point of this paper is to put forward the scheme of tool path in the milling process. The end profile of involute gear is modeled by an analytic method, and the equidistant contour of the profile of involute gear is established by using the principle of normal deviation, which provides an accurate position point for the cutting tool.

scholarly journals Research on Optimization Method of Tool Path in Five-Axis Process Singular Region

2020 ◽  
Author(s):  
Yujie Wang ◽  
Xin Shen ◽  
Yu Peng ◽  
Lixin Zhao
Keyword(s):  
Mathematical Model ◽  
Tool Path ◽  
Optimization Method ◽  
Rotating Shaft ◽  
Processing Efficiency ◽  
Machined Surface ◽  
Rapid Rotation ◽  
Singular Region ◽  
Axis Of Rotation ◽  
Five Axis

For the five-axis machine into the singular region in the process of parts processing, resulting in a discontinuous and rapid rotation of the axis of rotation of large angles. Based on the analysis of the cause of the obvious ripple on the machined surface and the influence on the machining precision, a mathematical model of the singular region is established, and an optimization method of the tool path in the singular region is proposed. The simulation and practical machining results show that the method can effectively overcome the problem of excessive movement of the rotating shaft in the Song singular region of 5-axis machine tool, and solve the surface corrugated defects caused by the problem, while improving the processing efficiency.

Mechanistic Model Based on the Actual Removal Volume during Simultaneous Five-Axis Milling

2011 ◽  
Vol 223 ◽  
pp. 713-722 ◽  
Author(s):  
Seok Won Lee ◽  
Andreas Nestler
Keyword(s):  
Cutting Force ◽  
Process Model ◽  
Tool Path ◽  
Mechanistic Model ◽  
Cutting Tools ◽  
Rake Angle ◽  
Milling Process ◽  
Cutting Edge ◽  
Nc Code ◽  
Five Axis

In this paper we present a novel mechanistic model of cutting process of the cylindrical tool by using the actual removal volume per tooth via NC simulation. The simulation kernel enables “virtually” cutting the workpiece in milling process per NC code, as well as calculating the removal volume per tooth which leads to predict the actual cutting force during simultaneous five-axis machining. Combined with the material removal simulation, the advanced mechanistic process model, which can enable the prediction of the cutting force and adjust the trajectory velocity of the cylindrical tools undergoing five-axis movement, is presented by applying the line integral along the cutting edge and taking the rake angle and cutting edge roundness into consideration. The novel methodology to adjust the cutting force by prevailing cutting tools undergoing multi-axis motion is to be validated by experiment and integrated into tool path planning systems.

The Effect of the Cutting Parameters on the Machined Surface Roughness

2017 ◽  
Vol 260 ◽  
pp. 219-226 ◽  
Author(s):  
Viktors Gutakovskis ◽  
Eriks Gerins ◽  
Janis Rudzitis ◽  
Artis Kromanis
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Tool Geometry ◽  
Machining Parameters ◽  
Machined Surface ◽  
Machined Surface Roughness

From the invention of turning machine or lathe, some engineers are trying to increase the turning productivity. The increase of productivity is following after the breakout in instrumental area, such as the hard alloy instrument and resistance to wear cutting surfaces. The potential of cutting speed has a certain limit. New steel marks and cutting surfaces types allow significantly increase cutting and turning speeds. For the most operation types the productivity increase begins from the feeding increase. But the increase of feeding goes together with machined surface result decreasement. Metal cutting with high feeding is one of the most actual problems in the increasing of manufacturing volume but there are some problems one of them is the cutting forces increasement and larger metal removal rate, which decrease the cutting tool life significantly. Increasing of manufacturing volume, going together with the cutting instrument technology and material evolution, such as the invention of the carbide cutting materials and wear resistant coatings such as TiC and Ti(C,N). Each of these coating have its own properties and functions in the metal cutting process. Together with this evolution the cutting tool geometry and machining parameters dependencies are researched. Traditionally for the decreasing the machining time of one part, the cutting parameters were increased, decreasing by this way the machining operation quantity. In our days the wear resistance of the cutting tools increasing and it is mostly used one or two machining operations (medium and fine finishing). The purpose of the topic is to represent the experimental results of the stainless steel turning process, using increased cutting speeds and feeding values, to develop advanced processing technology, using new modern coated cutting tools by CVD and PVD methods. After investigation of the machined surface roughness results, develop the mathematical model of the cutting process using higher values of the cutting parameters.

Performance evaluation of a tungsten carbide–based self-lubricant cutting tool

2016 ◽  
Vol 232 (10) ◽  
pp. 1825-1836 ◽  
Author(s):  
Ayyankalai Muthuraja ◽  
Selvaraj Senthilvelan
Keyword(s):  
Tungsten Carbide ◽  
Cutting Force ◽  
Tool Life ◽  
Solid Lubricant ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Chip Morphology ◽  
Machined Surface ◽  
Flank Surface

Tungsten carbide cutting tools with and without solid lubricant (WC-10Co-5CaF2 and WC-10Co) were developed in-house via powder metallurgy. The developed cutting tools and a commercial WC-10Co cutting tool were used to machine cylindrical AISI 1020 steel material under dry conditions. The cutting force and average cutting tool temperature were continuously measured. The cutting tool flank surface and chip morphology after specific tool life (5 min of cutting) were examined to understand tool wear. The flank wear of the considered cutting tools was also measured to quantify the cutting tool life. The surface roughness of the workpiece was measured to determine the machining quality. The developed cutting tool with solid lubricant (WC-10Co-5CaF2) generated 20%–40% less cutting force compared to that of the developed cutting tool without solid lubricant (WC-10Co). In addition, the finish of the workpiece surface improved by 16%–20% when it was machined by the solid lubricant cutting tool. The cutting tool with solid lubricant (WC-10Co-5CaF2) exhibited a 15%–18% reduction in flank wear. Curlier and smaller saw tooth chips were generated from the WC-10Co-5CaF2 cutting tool, confirming that less heat was generated during the cutting process, and the finish of the machined surface was also improved.

scholarly journals Highly Productive Tools For Turning And Milling

2015 ◽  
Vol 12 (2) ◽  
pp. 5-9
Author(s):  
Karol Vasilko
Keyword(s):  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Considerable Influence ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Surface Microgeometry ◽  
Tip Radius ◽  
Machining Productivity ◽  
The Relationship

Abstract Beside cutting speed, shift is another important parameter of machining. Its considerable influence is shown mainly in the workpiece machined surface microgeometry. In practice, mainly its combination with the radius of cutting tool tip rounding is used. Options to further increase machining productivity and machined surface quality are hidden in this approach. The paper presents variations of the design of productive cutting tools for lathe work and milling on the base of the use of the laws of the relationship among the highest reached uneveness of machined surface, tool tip radius and shift.

scholarly journals Development of Advanced Surface Engineering Technologies for the Benefit of Multipoint Cutting Tools

2009 ◽  
Vol 83-86 ◽  
pp. 1043-1050
Author(s):  
Mohammed Sarwar ◽  
Julfikar Haider
Keyword(s):  
High Speed ◽  
Surface Engineering ◽  
Cutting Tool ◽  
Systems Approach ◽  
Single Point ◽  
Cutting Tools ◽  
Substrate Material ◽  
End Users ◽  
Machined Surface ◽  
Edge Conditions

The benefits of applying advanced coatings on both single point and multipoint cutting tools such as improvement of productivity, tool life, machined surface quality etc. have been realised by the surface engineering researchers [1], commercial coaters [2-4] and end users [5]. The demand for advanced coatings in cutting tool industries is continually growing to meet the challenges of high speed machining, dry machining, near net-shape machining, machining of hard-to-cut materials etc.. Advanced coatings with excellent properties on flat coupon in a laboratory deposited by modern deposition technologies should not be taken for granted in improving the performance of complex shaped cutting tools [6] in aggressive cutting environments. This is because the end performance of coated cutting tools is not only dependant on the coating itself but also on the tool substrate material, geometry, surface finish and cutting edge conditions prior to coating deposition. The paper presents case studies with examples of successes and failures of advanced coatings on different multipoint cutting tools (e.g., milling cutters, bandsaws, circular saws, holesaws etc.). The future strategy for developing successful coating technology for cutting tools should be directed towards adopting a systems approach to bridge the communication gap amongst the cutting tool manufactures, tool coaters and end users.

scholarly journals Anticipatory Online Compensation of Tool Deflection Using a Priori Information from Process Planning

2021 ◽  
Vol 5 (3) ◽  
pp. 90
Author(s):  
Berend Denkena ◽  
Benjamin Bergmann ◽  
Tim Schumacher
Keyword(s):  
Tool Path ◽  
Force Measurement ◽  
A Priori ◽  
Flank Milling ◽  
Machined Surface ◽  
Reactive Compensation ◽  
Novel Approach ◽  
Corrective Movement ◽  
Force Variation ◽  
Priori Information

Removing excess material from build-up welding by milling is a critical step in the repair of blades from aircraft engines. This so-called recontouring is a very challenging machining task. Shape deviations often result from the deflection of tool and workpiece due to process forces. Considering the individuality of repair cases, compensation of those deflections by process force measurement and online tool path adaption is a very suitable method. However, there is one caveat to this reactive approach. Due to causality, a corrective movement, following a force variation, is always delayed by a finite reaction time. At this moment, though, the displacement has already manifested itself as a deviation in the machined surface. To overcome those limitations and to improve compensation beyond the reduction of control delays, this study proposes a novel approach of anticipatory online compensation. Flank-milling experiments with abrupt changes in the tool-workpiece engagement conditions are conducted to investigate the limitations of reactive compensation and to explore the potential of the new anticipatory approach.

Research on Triangularization of Parametric Surface Based on Surface Curvature

2014 ◽  
Vol 1061-1062 ◽  
pp. 1148-1152
Author(s):  
Wei Min Yang
Keyword(s):  
Tool Path ◽  
Cutting Tool ◽  
Layer By Layer ◽  
Parametric Surface ◽  
Parametric Surfaces ◽  
Local Curvature ◽  
Triangle Meshes ◽  
New Approach ◽  
Five Axis ◽  
Curvature Sphere

In five-axis tool path planning, interference between the cutting tool and parametric surface is very critical. One way of doing interference detection is first to discretize the surface. In this article we develop a new approach to discretize parametric surface adaptively by applying curvature sphere. Layer by layer the original surface is discretized into triangle meshes bases on the polyline between the triangulated and un-triangulated areas of the surface. Triangles generated with our method are adaptive, which means the density of the triangles changes with the local curvature value of the surface. We also develop a method to deal with triangle meshes overlapping problem. So triangle meshes generated with our algorithm is without gaps or any overlapping problem. Finally a criterion is suggested when the generation should stop. The algorithm has been tested for some parametric surfaces and the result turns out to be satisfactory.

Assessment of the Effects of Microgrooved Cutting Tool on the Machining Induced Residual Stress in Machining of Ti-6Al-4V

2016 ◽  
Author(s):  
Changqing Qiu ◽  
Jianfeng Ma ◽  
Shuting Lei
Keyword(s):  
Finite Element Method ◽  
Residual Stress ◽  
Compressive Residual Stress ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Three Dimensional ◽  
Rake Face ◽  
Machined Surface ◽  
Edge Distance ◽  
Cutting Inserts

In this paper, the effects of microgroove textured cutting tools on the residual stress on the machined surface of drying three-dimensional turning of Ti-6AL-4V are investigated using Finite Element Method (FEM). Microgrooves are designed and fabricated on the rake face of cemented carbide (WC/Co) cutting inserts. Specifically, the following microgroove parameters are examined: microgroove width, microgroove depth, and edge distance (the distance from cutting edge to the first microgroove). Their effects are assessed in terms of the circumferential residual stress. It is found that microgroove textured cutting tools can lower the detrimental tensile residual stress and induce beneficial compressive residual stress on the machined surface. The microgroove width, microgroove depth, and edge distance all have influence on residual stress on the machined surface in their own ways. This research provides insightful guidance for optimizing the fatigue life of the components by inducing beneficial compressive residual stress on the machined surface.

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