Five Axis Swept Profiles of Torus Like Cutters via Separation of Inner and Outer Characteristic Curves

2018 ◽  
Author(s):  
Eyyup Aras
Keyword(s):  
Tool Path ◽  
Rotation Axis ◽  
Linear Interpolation ◽  
Unit Vector ◽  
Industrial Applications ◽  
Body Motion ◽  
Moving Frames ◽  
Closed Form Solutions ◽  
Toroidal Surface ◽  
Five Axis

A broadly applicable formulation for identifying the swept profiles (SWP) generated by subsets of a toroidal surface is presented. While the problem of locating the entire SWP of a torus has been extensively addressed in the literature, this rarely addressed problem is of significance to NC machining with non-standard shape of milling tools. A torus, generated by revolving a circle about an axis coplanar with the circle, is made up of inner and outer parts of a tube. The common use of the torus is in a fillet-end mill which contains only the fourth quadrant of a cross section of the tube. However, in the industrial applications the different regions of the torus geometry appear. Especially we can see this on the profile cutters, such as the corner-rounding and concave-radius end mills. Also to the best of our knowledge, the interior of the torus-tube is either neglected or represented by B-spline curves in literature. In case of common milling tool surfaces such as sphere, cylinder and frustum there exists only one SWP in any instance of a tool movement. But, in case of the toroidal surface there exist two sophisticated SWPs and we need to consider only one of them in tool swept envelope generation. Therefore, considering the complexity of five-axis tool motions there is a need not only to distinguish the front from the rear of the cutter but also the exterior from the interior of a tube. This paper presents a methodology and algorithms for analytically formulating the SWP of any sub-set of the torus in five-axis tool motions. By introducing the rigid body motion theory, two moving frames along with a fixed frame are defined. Arbitrary poses of a tool between tool path locations are interpolated by a spherical linear interpolation (slerp) whose effect is a rotation with uniform angular velocity around a fixed rotation axis. For the problem of NC simulation, by using the envelope theory the closed-form solutions of swept profiles are formulated as two-unit vector functions.

scholarly journals Tracing sub-surface swept profiles of tapered toroidal end mills between level cuts

2019 ◽  
Vol 6 (4) ◽  
pp. 629-646
Author(s):  
Eyyup Aras
Keyword(s):  
Closed Form ◽  
Rotation Axis ◽  
Computational Cost ◽  
Industrial Applications ◽  
Machining Process ◽  
Moving Frames ◽  
Factors Affecting ◽  
Tube Cross Section ◽  
Closed Form Solutions ◽  
Characteristic Points

Abstract Development of closed-form solutions and algorithms for constructing sub-surface swept profiles (SWP) of toroidal and conical bodies is presented in this paper. While the problem of identifying the entire SWP of such surfaces has been extensively investigated in extant studies, construction of subsurface SWPs has rarely been addressed despite the subject being of great significance to machining process employing nonstandard-shaped NC tools. Torus shapes considered in extant literature are restricted to the fourth quadrant of a tube cross section. In industrial applications, however, profile cutters contain different regions of a toroidal surface. To identify SWP elements in the proposed study, a single analytical expression in one variable has been deduced using two moving frames. The basic idea behind such a formulation is to employ the one-to-many strategy, which greatly reduces the computational cost and effort. Algorithms to identify feasible domains of SWP parameters at each level cut, where toroidal and conical surfaces meet, have also been proposed in this study. This is important, since cutting a tool surfaces along the rotation axis divides SWP-parameter domains into non overlapping sets of intervals that must be addressed for each tool posture. In addition, this study demonstrates that for certain tool postures, while C1 continuity between sub-surfaces is satisfied, the SWP connectivity is lost at some points. To locate these so called singular-characteristic points, some precomputation steps have been performed. Lastly, several factors affecting the smoothness of SWPs have been identified and discussed. Highlights Closed form solutions have been derived for constructing the sub-swept profiles of toroidal tools. Three algorithms have been presented to identify the feasible domains of swept profile parameters. In order to locate the singular-characteristic points some precomputation steps have been carried out. Finally, several factors, affecting the smoothness of the swept profiles, have been identified.

Five-Axis HSM Tool-Path Planning of Integral Impeller

2010 ◽  
Vol 426-427 ◽  
pp. 572-576
Author(s):  
Can Zhao ◽  
Y.Y. Guo ◽  
Guang Bin Bu
Keyword(s):  
High Speed ◽  
Control Algorithm ◽  
Tool Path ◽  
Control Method ◽  
Interpolation Method ◽  
Linear Interpolation ◽  
Normal Vector ◽  
Manufacture Process ◽  
Five Axis ◽  
Uniform Change

There are two key problems in the manufacture process of impeller with HSM(High Speed Machining). One is the collision between tool and blade, the other is gnawed-cutting arisen by non-uniform change of the cutter axis. The control algorithm of collision-free cutter-axis was described and applied in this paper. The cutter-axis vector was optimized by quaternary linear interpolation method to make normal vector of blade changing continuous, so. These methods were synthetically used in the manufacture experiment. And the qualified impeller was produced. It indicated that the tool vector control method was feasible.

A Machining Test to Reflect Dynamic Machining Accuracy of Five-Axis Machine Tools

2012 ◽  
Vol 622-623 ◽  
pp. 414-419 ◽  
Author(s):  
Wen Ping Mou ◽  
Zhi Yong Song ◽  
Zhi Ping Guo ◽  
Li Min Tang
Keyword(s):  
Machine Tools ◽  
Tool Path ◽  
Industrial Applications ◽  
Machining Accuracy ◽  
Surface Machining ◽  
The Real ◽  
Machining Test ◽  
Five Axis ◽  
Kinematic Errors

NAS (National Aerospace Standard) 979 is the only standard well known in industry describing a five-axis machining test for measuring kinematic errors of five-axis machine tools. As it cannot reflect the tool path characteristics of typical ruled surface machining, five-axis machine tools which passed the NAS test may not have the ability to satisfy the requirement of the real industrial applications. To fill this gap between the NAS test and the real industrial applications, an “S” machining test is proposed in this paper. The case study shows that the proposed machining test is feasible and practicable.

Research on Five-Axis Dual-NURBS Adaptive Interpolation Algorithm for Flank Milling

2010 ◽  
Vol 443 ◽  
pp. 330-335 ◽  
Author(s):  
Yu Han Wang ◽  
Jing Chun Feng ◽  
Sun Chao ◽  
Ming Chen
Keyword(s):  
Tool Path ◽  
Flank Milling ◽  
Interpolation Algorithm ◽  
Machining Time ◽  
Surface Machining ◽  
Tool Axis ◽  
Scanning Area ◽  
Nurbs Interpolation ◽  
Milling Method ◽  
Five Axis

In order to exploit the advantages of five-axis flank milling method for space free surface machining to the full, a definition of non-equidistant dual-NURBS tool path is presented first. On this basis, the constraint of velocity of points on the tool axis and the constraint of scanning area of the tool axis are deduced. Considering both of these constraints, an adaptive feed five-axis dual-NURBS interpolation algorithm is proposed. The simulation results show that the feedrate with the proposed algorithm satisfies both of the constraints and the machining time is reduced by 38.3% in comparison with the constant feed interpolator algorithm.

Collision-Free Tool Path Generation for Five-Axis High Speed Machining

2011 ◽  
Vol 474-476 ◽  
pp. 961-966 ◽  
Author(s):  
Li Qiang Zhang ◽  
Min Yue
Keyword(s):  
Image Analysis ◽  
Collision Detection ◽  
High Speed ◽  
Tool Path ◽  
Geometric Model ◽  
High Speed Machining ◽  
Analysis Method ◽  
Geometric Information ◽  
Detection Approach ◽  
Five Axis

Collision detection is a critical problem in five-axis high speed machining. Using a combination of process simulation and collision detection based on image analysis, a rapid detection approach is developed. The geometric model provides the cut geometry for the collision detection and records a dynamic geometric information for in-process workpiece. For the precise collision detection, a strategy of image analysis method is developed in order to make the approach efficient and maintian a high detection precision. An example of five-axis machining propeller is studied to demonstrate the proposed approach. It has shown that the collision detection task can be achieved with a near real-time performance.

Global optimization of tool path for five-axis flank milling with a conical cutter

2010 ◽  
Vol 42 (10) ◽  
pp. 903-910 ◽  
Author(s):  
LiMin Zhu ◽  
Gang Zheng ◽  
Han Ding ◽  
YouLun Xiong
Keyword(s):  
Global Optimization ◽  
Tool Path ◽  
Flank Milling ◽  
Five Axis

scholarly journals Optimisation of Planning Parameters for Machining Blade Electrode Micro-Fillet with Scallop Height Modelling

Micromachines ◽  
2021 ◽  
Vol 12 (3) ◽  
pp. 237
Author(s):  
Yue Liu ◽  
Zhanqiang Liu ◽  
Wentong Cai ◽  
Yukui Cai ◽  
Bing Wang ◽  
...  
Keyword(s):  
Path Planning ◽  
Tilt Angle ◽  
Tool Path ◽  
End Milling ◽  
Tool Path Planning ◽  
Scallop Height ◽  
Aero Engine ◽  
Tool Tilt Angle ◽  
Five Axis ◽  
Height Model

Aero-engine blades are manufactured by electroforming process with electrodes. The blade electrode is usually machined with five-axis micromilling to get required profile roughness. Tool path planning parameters, such as cutting step and tool tilt angle, have a significant effect on the profile roughness of the micro-fillet of blade electrode. In this paper, the scallop height model of blade electrode micro-fillet processed by ball-end milling cutter was proposed. Effects of cutting step and tool tilt angle the machined micro-fillet profile roughness were predicted with the proposed scallop height model. The cutting step and tool tilt angle were then optimised to ensure the contour precision of the micro-fillet shape requirement. Finally, the tool path planning was generated and the machining strategy was validated through milling experiments. It was also found that the profile roughness was deteriorated due to size effect when the cutting step decreased to a certain value.

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