Admissible Tool Orientation Control of 5-Axis Complex Surface Machining for CAD/CAM Systems

1997 ◽  
Author(s):  
Yuan-Shin Lee
Keyword(s):  
Tool Path ◽  
Orthogonal Cutting ◽  
Complex Surface ◽  
Surface Shape ◽  
Path Generation ◽  
Localization Algorithm ◽  
Tool Orientation ◽  
Orientation Control ◽  
Rear Gouging ◽  
Cutter Path Generation

Abstract This paper presents a methodology and algorithms of admissible tool orientation control for gouging avoidance in 5-axis machining. A method is proposed to find the admissible tool orientation by considering both local and global surface shapes. A filleted endmill is used in this study for 5-axis machining. Based on the evaluation of local surface shape, a geometry analysis method is developed to first find a feasible tool orientation for gouging avoidance along two orthogonal cutting planes. Adjacent geometry is then taken into consideration for detecting possible rear gouging. A localization algorithm is developed for filleted endmills to identify potential rear gouging area. Both the circular approximation and the detailed gouging checking methods are proposed for rear gouging correction. The techniques presented in this paper can be used to eliminate errors of tool paths as they are generated. Unlike the traditional graphical verification and user-interactive correction of tool path generation, the proposed methodology can be used to automate the planning and programming of cutter path generation for 5-axis machining.

Tool Orientation Planning in Milling With Process Dynamic Constraints: A Minimax Optimization Approach

2018 ◽  
Vol 140 (11) ◽  
Author(s):  
Tao Huang ◽  
Xiao-Ming Zhang ◽  
Jürgen Leopold ◽  
Han Ding
Keyword(s):  
Tool Path ◽  
End Milling ◽  
Tool Path Generation ◽  
Optimization Approach ◽  
Path Generation ◽  
Tool Orientation ◽  
Minimax Optimization ◽  
Ball End Milling ◽  
Dynamic Constraints ◽  
Five Axis

In five-axis milling process, the tool path generated by a commercial software seldom takes the dynamics of the machining process into account. The neglect of process dynamics may lead to milling chatter, which causes overcut, quick tool wear, etc., and thus damages workpiece surface and shortens tool life. This motivates us to consider dynamic constraints in the tool path generation. Tool orientation variations in five-axis ball-end milling influence chatter stability and surface location error (SLE) due to the varying tool-workpiece immersion area and cutting force, which inversely provides us a feasible and flexible way to suppress chatter and SLE. However, tool orientations adjustment for suppression of chatter and SLE may cause drastic changes of the tool orientations and affects surface quality. The challenge is to strike a balance between the smooth tool orientations and suppression of chatter and SLE. To overcome the challenge, this paper presents a minimax optimization approach for planning tool orientations. The optimization objective is to obtain smooth tool orientations, by minimizing the maximum variation of the rotational angles between adjacent cutter locations, with constraints of chatter-free and SLE threshold. A dedicated designed ball-end milling experiment is conducted to validate the proposed approach. The work provides new insight into the tool path generation for ball-end milling of sculpture surface; also it would be helpful to decision-making for process parameters optimization in practical complex parts milling operations at shop floor.

A New Principle of CNC Tool Path Planning for Three-Axis Sculptured Part Machining—A Steepest-Ascending Tool Path

2004 ◽  
Vol 126 (3) ◽  
pp. 515-523 ◽  
Author(s):  
Zezhong C. Chen ◽  
Geoffrey W. Vickers ◽  
Zuomin Dong
Keyword(s):  
Path Planning ◽  
Tool Path ◽  
Tool Path Generation ◽  
Surface Shape ◽  
Sculptured Surface ◽  
Machining Efficiency ◽  
Path Generation ◽  
Tool Path Planning ◽  
Tool Paths ◽  
Sculptured Parts

Three-axis CNC milling is often used to machine sculptured parts. Due to the complex surface shape of these parts, well-planned tool paths can significantly increase the machining efficiency. In this work a new principle of CNC tool path planning for 3-axis sculptured surface machining is proposed. Generic formula to calculate the steepest tangent direction of a sculptured surface is derived, and the algorithm of the steepest-ascending tool path generation is introduced. A single steepest-ascending tool path has been verified to be more efficient than a single tool path of any other type. The relationship between machining efficiency and three key variables, tool feed direction, cutter shape, and surface shape, is revealed. The newly introduced principle is used in planning tool paths of a sculptured surface to demonstrate the advantages of the steepest-ascending tool paths. This new tool path scheme is further integrated into the more advanced steepest-directed and iso-cusped (SDIC) tool path generation technique. Applications of the new tool path principle and the SDIC tool paths to the machining of sculptured parts are demonstrated.

C23 Tool Path Generation for Complex Surface in case of 5-Axis Machine Tool

2008 ◽  
Vol 2008.7 (0) ◽  
pp. 189-190
Author(s):  
Takehisa KOIZUMI ◽  
Keiichi NAKAMOTO ◽  
Tohru ISHIDA ◽  
Yoshimi TAKEUCHI
Keyword(s):  
Machine Tool ◽  
Tool Path ◽  
Complex Surface ◽  
Tool Path Generation ◽  
Path Generation

Configuration-Space Searching and Optimizing Tool Orientations for 5-Axis Machining

Manufacturing ◽  
2002 ◽  
Author(s):  
Cha-Soo Jun ◽  
Yuan-Shin Lee ◽  
Kyungduck Cha
Keyword(s):  
Configuration Space ◽  
High Performance ◽  
Tool Path ◽  
Sculptured Surface ◽  
Tool Orientation ◽  
Machined Surface ◽  
Surface Error ◽  
Surface Machining ◽  
Sculptured Surface Machining ◽  
Rear Gouging

This paper presents a methodology and algorithms of optimizing and smoothing the tool orientation control for 5-axis sculptured surface machining. A searching method in the machining configuration space (C-space) is proposed to find the optimal tool orientation by considering the local gouging, rear gouging and global tool collision in machining. Based on the machined surface error analysis, a boundary search method is developed first to find a set of feasible tool orientations in the C-space to eliminate gouging and collision. By using the minimum cusp height as the objective function, we first determine the locally optimal tool orientation in the C-space to minimize the machined surface error. Considering the adjacent part geometry and the alternative feasible tool orientations in the C-space, tool orientations are then globally optimized and smoothed to minimize the dramatic change of tool orientation during machining. The developed method can be used to automate the planning and programming of tool path generation for high performance 5-axis sculptured surface machining. Computer implementation and examples are also provided in the paper.

scholarly journals Tool Path Generation, for Complex Surface Machining, Using Point Cloud Data

Procedia CIRP ◽  
2015 ◽  
Vol 26 ◽  
pp. 397-402 ◽  
Author(s):  
Anadil Masood ◽  
Rooha Siddiqui ◽  
Michelle Pinto ◽  
Hira Rehman ◽  
Maqsood A. Khan
Keyword(s):  
Point Cloud ◽  
Tool Path ◽  
Complex Surface ◽  
Tool Path Generation ◽  
Path Generation ◽  
Point Cloud Data ◽  
Surface Machining ◽  
Cloud Data

Isoscallop of Self-Adaptive Tool Orientation with Toroidal Cutter under Optimum Orientation of MCPs

2012 ◽  
Vol 562-564 ◽  
pp. 713-716 ◽  
Author(s):  
Ying Chen ◽  
Yi Qiang Wang
Keyword(s):  
Tool Path ◽  
End Milling ◽  
Complex Problem ◽  
Strip Width ◽  
Free Form ◽  
Tool Orientation ◽  
Constant Scallop Height ◽  
Cutter Path ◽  
Cutter Path Generation ◽  
Free Form Surfaces

End-milling of free-form surfaces on 5-sxis NC tools is a complex problem which has been studied by a large number of research scientists. When end-milling non-convex surfaces, there is a risk of interference between the tool and the surface. This paper presents a new approach to generate gouging-free tool path for constant scallop-height machining using 5-axis toroidal milling. Based on second-order approximations of the machined strip width, we present locally optimal cutting positions for cutting directions. The largest machined strip width of iso-scallop and the corresponding gouging-avoidance tool orientation are calculated. In the cutter path generation procedures, the master cutter paths have been chosen from the minimum curvature loci of the surface. The tool path generated by this method are also compared with that of the long edge of surface as the MCP, the results of simulation show that the method can yield a reduction in line segments of tool path . Velocity curve and acceleration curve are smoother.

scholarly journals A New Optimal Method of Tool Path Generation for Slow Tool Servo Turning of Complex Surface

2020 ◽  
Vol 20 (6) ◽  
pp. 733-747
Author(s):  
Hangyan Guo ◽  
Min Kang ◽  
Wei Zhou ◽  
Hengtai Niu ◽  
Bingwei Song
Keyword(s):  
Tool Path ◽  
Complex Surface ◽  
Tool Path Generation ◽  
Path Generation ◽  
Optimal Method ◽  
Slow Tool Servo
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