Geometric Modeling of Cutter/Workpiece Engagements in 3-Axis Milling Using Polyhedral Models

2007 ◽  
Author(s):  
Eyyup Aras ◽  
Derek Yip-Hoi
Keyword(s):  
Cutting Forces ◽  
Geometric Modeling ◽  
Tool Path ◽  
Cutting Tool ◽  
Milling Process ◽  
Mapping Technique ◽  
Depth Of Cut ◽  
Modeling Methodology ◽  
Machining System ◽  
Engagement Angle

Modeling the milling process requires cutter/workpiece engagement (CWE) geometry in order to predict cutting forces. The calculation of these engagements is challenging due to the complicated and changing intersection geometry that occurs between the cutter and the in-process workpiece. This geometry defines the instantaneous intersection boundary between the cutting tool and the in-process workpiece at each location along a tool path. This paper presents components of a robust and efficient geometric modeling methodology for finding CWEs generated during 3-axis machining of surfaces using a range of different types of cutting tool geometries. A mapping technique has been developed that transforms a polyhedral model of the removal volume from Euclidean space to a parametric space defined by location along the tool path, engagement angle and the depth-of-cut. As a result, intersection operations are reduced to first order plane-plane intersections. This approach reduces the complexity of the cutter/workpiece intersections and also eliminates robustness problems found in standard polyhedral modeling and improves accuracy over the Z-buffer technique. The CWEs extracted from this method are used as input to a force prediction model that determines the cutting forces experienced during the milling operation. The reported method has been implemented and tested using a combination of commercial applications. This paper highlights ongoing collaborative research into developing a Virtual Machining System.

Geometric Modeling of Cutter/Workpiece Engagements in Three-Axis Milling Using Polyhedral Representations

2008 ◽  
Vol 8 (3) ◽  
Author(s):  
Eyyup Aras ◽  
Derek Yip-Hoi
Keyword(s):  
Cutting Forces ◽  
Geometric Modeling ◽  
Tool Path ◽  
Cutting Tool ◽  
Milling Process ◽  
Mapping Technique ◽  
Depth Of Cut ◽  
Modeling Methodology ◽  
Machining System ◽  
Engagement Angle

Modeling the milling process requires cutter/workpiece engagement (CWE) geometry in order to predict cutting forces. The calculation of these engagements is challenging due to the complicated and changing intersection geometry that occurs between the cutter and the in-process workpiece. This geometry defines the instantaneous intersection boundary between the cutting tool and the in-process workpiece at each location along a tool path. This paper presents components of a robust and efficient geometric modeling methodology for finding CWEs generated during three-axis machining of surfaces using a range of different types of cutting tool geometries. A mapping technique has been developed that transforms a polyhedral model of the removal volume from the Euclidean space to a parametric space defined by the location along the tool path, the engagement angle, and the depth of cut. As a result, intersection operations are reduced to first order plane-plane intersections. This approach reduces the complexity of the cutter/workpiece intersections and also eliminates robustness problems found in standard polyhedral modeling and improves accuracy over the Z-buffer technique. The CWEs extracted from this method are used as input to a force prediction model that determines the cutting forces experienced during the milling operation. The reported method has been implemented and tested using a combination of commercial applications. This paper highlights ongoing collaborative research into developing a virtual machining system.

Geometric Modeling of Cutter/Workpiece Engagements for Helical Milling With Flat End Mills

2007 ◽  
Author(s):  
Eyyup Aras ◽  
Derek Yip-Hoi
Keyword(s):  
Geometric Modeling ◽  
High Speed ◽  
Tool Path ◽  
Cutting Tool ◽  
Milling Process ◽  
Helical Milling ◽  
Mapping Technique ◽  
Depth Of Cut ◽  
Modeling Methodology ◽  
End Mills

Helical milling is a 3-axis machining operation where a cutting tool is feed along a helix. This operation is used in ramp-in and ramp-out moves when the cutting tool first engages the workpiece, for contouring and for hole machining. It is increasingly finding application as a means for roughing large amounts of material during high speed machining. Modeling the helical milling process requires cutter/workpiece engagements (CWEs) geometry in order to predict cutting forces. The calculation of these engagements is challenging due to the complicated and changing intersection geometry that occurs between the cutter and the in-process workpiece. In this paper we present a geometric modeling methodology for finding engagements during helical milling with flat end mills. A mapping technique has been developed that transforms a polyhedral model of the removal volume from Euclidean space to a parametric space defined by location along the tool path, engagement angle and the depth-of-cut. As a result, intersection operations are reduced to first order plane-plane intersections. This approach reduces the complexity of the cutter/workpiece intersections and also eliminates robustness problems found in standard polyhedral modeling and improves accuracy over the Z-buffer technique. The reported method has been implemented and tested using a combination of commercial applications. This paper highlights ongoing collaborative research into developing a Virtual Machining System.

A Solid Modeler Approach for Extracting Cutter Workpiece Engagements in Milling

2008 ◽  
Author(s):  
Eyyup Aras ◽  
Derek Yip-Hoi
Keyword(s):  
Geometric Modeling ◽  
Cutting Tools ◽  
Free Form ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Modeling Methodology ◽  
Engagement Angle ◽  
Solid Modeler ◽  
Free Form Surfaces ◽  
Boundary Curves

This paper presents a Solid modeling methodology for finding Cutter Workpiece Engagements (CWEs) generated during 3+2 -axis machining (spindle can tilt) of free – form surfaces using a range of different types of cutting tools and tool paths. Swept volumes of the cutters are generated utilizing the envelope theory. For the CWE extractions the removal volumes of the cutter constituent surfaces are used. For this purpose the cutter surfaces are decomposed with respect to the tool feed direction and then they intersected with their removal volumes for obtaining the boundary curves of the closed CWE area. The CWE boundary curves are mapped from Euclidean space to a parametric space defined by the engagement angle and the depth-of-cut for a given tool geometry. The reported method has been implemented using a commercial geometric modeler (ACIS) which is selected to be the kernel around which the geometric simulator is built. The described geometric methodology is being developed as part of a Virtual Milling methodology that combines the geometric modeling aspects of milling material removal with the modeling of the process.

scholarly journals Stability analysis for a single-point cutting tool deflection in turning operation

2019 ◽  
Vol 11 (6) ◽  
pp. 168781401985318
Author(s):  
Amon Gasagara ◽  
Wuyin Jin ◽  
Angelique Uwimbabazi
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Cutting Tool ◽  
Single Point ◽  
Three Dimensional ◽  
High Speed Steel ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Beam Model ◽  
Tool Deflection

In this article, a new model of regenerative vibrations due to the deflection of the cutting tool in turning is proposed. The previous study reported chatter as a result of cutting a wavy surface of the previous cut. The proposed model takes into account cutting forces as the main factor of tool deflection. A cantilever beam model is used to establish a numerical model of the tool deflection. Three-dimensional finite element method is used to estimate the tool permissible deflection under the action of the cutting load. To analyze the system dynamic behavior, 1-degree-of-freedom model is used. MATLAB is used to compute the system time series from the initial value using fourth-order Runge–Kutta numerical integration. A straight hard turning with minimal fluid application experiment is used to obtain cutting forces under stable and chatter conditions. A single-point cutting tool made from high-speed steel is used for cutting. Experiment results showed that for the cutting parameters above 0.1mm/rev feed and [Formula: see text]mm depth of cut, the system develops fluctuations and higher chatter vibration frequency. Dynamic model vibration results showed that the cutting tool deflection induces chatter vibrations which transit from periodic, quasi-periodic, and chaotic type.

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.

MATHEMATICAL MODEL FOR CHIP GEOMETRY CALCULATION IN FIVE-AXIS MILLING

2015 ◽  
Vol 77 (23) ◽  
Author(s):  
Hendriko Hendriko
Keyword(s):  
Coordinate System ◽  
Inclination Angle ◽  
Mapping Technique ◽  
Depth Of Cut ◽  
Work Piece ◽  
Primary Input ◽  
Proposed Model ◽  
Engagement Angle ◽  
Scheduling Method ◽  
Five Axis

This paper presents the method to calculate the geometries of instantaneous chip in five-axis milling. The inclination angle changes in between two consecutive CC-points were taken into account in the calculation. In the first stage, the engagement angle, the axial depth of cut and cut width were determined through the mapping technique. The engagement point of the Work piece Coordinate System (WCS) was mapped to a Tool Coordinate System (TCS). In the second stage, the engagement angle and depth of cut, which were defined in the first stage were then used as a primary input to obtain the cut thickness and cut width. Two simulation tests have been presented to verify the ability of the proposed model to predict the cut geometry. The first tests revealed that the inclination angle makes the size of the cut thickness and cut width fluctuate. The cut width increased when the tool inclination angle increased. For the cut thickness, its magnitude was influenced by two effects, the orientation effect and the tooth path effect. The final result was a compromise between these two effects. In the second simulation test, the proposed model was successfully implemented to support the feedrate scheduling method.

scholarly journals Eliminating the Effect of Uncertainties of Cutting Forces by Fuzzy Controller for Robots in Milling Process

2020 ◽  
Vol 10 (5) ◽  
pp. 1685 ◽  
Author(s):  
Khoi Bui Phan ◽  
Hai Thanh Ha ◽  
Sinh Vinh Hoang
Keyword(s):  
Differential Equations ◽  
Dynamic Model ◽  
Cutting Forces ◽  
Fuzzy Controller ◽  
Driving Forces ◽  
Milling Process ◽  
Industrial Robots ◽  
Machining Process ◽  
Depth Of Cut ◽  
Input And Output

This study presents a method of controlling robots based on fuzzy logic to eliminate the effect of uncertainties that are generated by the cutting forces in milling process. The common method to control industrial robots is based on the robot dynamic model and the differential equations of motion to compute the control values. The quantities in the differential equations of the motion of robots are complex and difficult to determine fully and accurately. The interaction forces between the cutting tool and the workpiece are the cutting forces, which are generated during the machining process. It is difficult to calculate the cutting force because it depends on many factors such as material of the machining part, depth of cut, feed rate, etc. This article presents the fuzzy rule system and the selection of the physical value domain of input and output variables of the fuzzy controller. The fuzzy rules are applied in this article to allow us to compute the driving forces based on the errors of input and output signals of the joint positions and velocities, thereby avoiding the calculation of cutting forces. This article shows the simulation results of the fuzzy controller and comparison with the results of the conventional controller when the dynamic model is assumed to be correctly determined. The achieved results are reliable and facilitate the research and application of a fuzzy controller to mechanical processing robots in general and milling machining in particular.

Corrosion Behaviour and Microhardness during Dry and Flood Milling of Ti-6Al-4V Alloy

2019 ◽  
Vol 796 ◽  
pp. 91-96
Author(s):  
Esther Titilayo Akinlabi ◽  
Ipfi Mathoho ◽  
Mukuna Patrick Mubiayi
Keyword(s):  
Corrosion Resistance ◽  
Cutting Tool ◽  
Corrosion Behaviour ◽  
Milling Process ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Dry Milling ◽  
Milled Surface ◽  
Milling Condition

Milling process is the removal of unwanted materials so as to produce the required shape. The purpose of this study was to investigate the effect of milling process parameters and the cooling technique on corrosion behaviour and microhardness of TI-6AL-4V. Milling of Ti-6Al-4V was carried out using tungsten carbide cutting tool while varying spindle speed (120,150, and 180 rev/min), depth of cut (1, 1.5 and 2 mm) and the feed rate remained unchanged at 4.6 mm/min. Subsequent to milling, characterization of subsurface microhardness and corrosion behaviour was conducted. It was found that varying spindle speed and depth of cut had an impact on microhardness. Furthermore, it was noticed that the type of milling condition (flood and dry milling) affected the subsurface microhardness and the corrosion behavior. The corrosion resistance of the milled surface was generated at 180 rev/min and 150 rev/min for the dry and flood milling respectively. Furthermore, the most corrosion resistance was obtained at 2 mm and 1.5 mm depth of cut during dry and flood milling respectively.

Key Technologies Research for Impellers Machining Based on NX

2011 ◽  
Vol 101-102 ◽  
pp. 1031-1034
Author(s):  
Xian Yi Li ◽  
Jian Zhong Fu ◽  
Ji Qiang Li
Keyword(s):  
Tool Path ◽  
Cutting Tool ◽  
Milling Process ◽  
Tool Path Generation ◽  
Machining Accuracy ◽  
Post Processing ◽  
Nc Code ◽  
Nc Program ◽  
Key Technologies ◽  
Nc Machine

Tool path generation, post-processing and verification and simulation of NC program are key technologies which are investigated in this research for manufacturing impellers. Generation of tool path aims at producing the cutting tool path. Post-processing transforms the cutter location file (CLSF file) of the tool path to the NC code which NC machine can recognize. Verification and simulation of NC program aims at proving the accuracy of program, thus the interference and collision can be avoided. When tool path is planned, increasing the machining efficiency during the rough and semi-finish milling process is the main consideration. Increasing machining accuracy is an important consideration for final finish milling.

Analysis of Force Shape Characteristics and Detection of Depth-of-Cut Variations in End Milling

2004 ◽  
Vol 127 (3) ◽  
pp. 454-462 ◽  
Author(s):  
Liuqing Yang ◽  
Richard E. DeVor ◽  
Shiv G. Kapoor
Keyword(s):  
Cutting Forces ◽  
Analytical Approach ◽  
End Milling ◽  
Milling Process ◽  
Depth Of Cut ◽  
End Mill ◽  
Shape Characteristics ◽  
Cutting Experiments ◽  
End Milling Process ◽  
Degree Of Overlap

This paper proposes an analytical approach to detect depth-of-cut variations based on the cutting-force shape characteristics in end milling. Cutting forces of a single-flute end mill are analyzed and classified into three types according to their shape characteristics. Cutting forces of a multiple-flute end mill are then classified by considering both the cutting types of the corresponding single-flute end mill and the degree of overlap of successive flutes in the cut. Force indices are extracted from the cutting forces and depth-of-cut variations are detected based on the changes of the force shape characteristics via the force indices in an end-milling process. The detection methodology is validated through cutting experiments.

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