Tool Path Generation Method for High-Quality Machining of Free-Form Surfaces

2020 International Symposium on Flexible Automation ◽

10.1115/isfa2020-9658 ◽

2020 ◽

Author(s):

Yuki Takanashi ◽

Hideki Aoyama

Keyword(s):

Tool Path ◽

High Accuracy ◽

Tool Path Generation ◽

Free Form ◽

Machining Accuracy ◽

Path Generation ◽

High Quality ◽

Nc Program ◽

Free Form Surface ◽

Free Form Surfaces

Abstract Machining data (NC program) is generated by a CAM system, which generates the tool path from the target shape as a plane approximation surface instead of a free-form surface. Owing to this plane approximation, machining accuracy is reduced. In this paper, we propose a method to process the shape with high accuracy by defining the areas where accuracy is not required as a plane approximation surface and defining the part where accuracy is required as free-form surfaces.

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Tool Path Generation for Machining Shrouded Turbine Blisk

Manufacturing Engineering and Materials Handling Engineering ◽

10.1115/imece2004-60183 ◽

2004 ◽

Cited By ~ 3

Author(s):

Xiang Wu ◽

Wansheng Zhao ◽

R. Du

Keyword(s):

Tool Path ◽

Tool Path Generation ◽

New Method ◽

Free Form ◽

Machining Accuracy ◽

Geometrical Shape ◽

Path Generation ◽

Simultaneous Control ◽

Turbine Blisk ◽

Free Form Surfaces

Shrouded turbine blisk is an important component for liquid-propellant rocket engine, airplane engine and some other high-power turbine machines. It is made from high-temperature alloy (e.g., nickel-base alloy and titanium alloy) and hence, is difficult to machine. In addition, its geometrical shape is complicated involving many semi-enclosed, twisted, free-form surfaces. In order to ensure the best performance, its dimension accuracy is very demanding. For the moment, an effective way to manufacture shrouded turbine blisk is Electrical Discharge Machining (EDM) using form tools (form electrodes). However, owing to its complicated geometry, existing commercial CAM systems cannot generate the interference-free tool path for it. In this paper, a new tool path generation method is presented. The new method is base on the quadratic programming and CNC multi-axis simultaneous control. It generates tool path in two steps. First, a feasible zone is generated by coarse search, which gives an elementary path for form tool feed. Then, within the feasible zone the actual NC tool path is found by fine search through CNC multi-axis simultaneous control simulation. In practice, a form tool follows the interference-free tool path moving into the twisted passages of blisk for machining, while the blisk is turning by a CNC turntable. The new method is validated experimentally. Compared to the existing methods, it can obtain high machining efficiency and high machining accuracy. Experimental results indicate that the new method is accurate. This new method can also be applied to many other machining applications involving complicated geometrical shape.

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Tool Path Generation Method of Equal Approximation Error for Free-Form Surface in High Speed Machining

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.102-104.544 ◽

2010 ◽

Vol 102-104 ◽

pp. 544-549 ◽

Cited By ~ 1

Author(s):

Chun Jiang Zhou ◽

Hong Chun Chen

Keyword(s):

High Speed ◽

Tool Path ◽

Cutting Tool ◽

End Milling ◽

Approximation Error ◽

Tool Path Generation ◽

Free Form ◽

Path Generation ◽

High Speed Machining ◽

Free Form Surface

The development of surface high-speed machining has put forward higher demands for uniform cutting load and smooth cutting tool path. Most current tool-path planning methods are based on constant scallop height, but they have the disadvantage of path point redundancy during the path discretization process. To overcome the problem, a tool path generation method of equal approximation error in each step for free-form surface is presented based on geodesic principle and curvature judgment. In this method, the NURBS curve is employed to realize smooth transition for adjacent two tool paths in high-speed machining. A certain angle of inclination of flat-end milling cutter during multi-axis machining improves the machining efficiency. Because of the advantage of this machining condition, the cutter location point generation algorithm during the machining condition is given by the method. The method is verified and simulated by C++. Experiment results proved that it can obtain uniform cutting load and continuous smooth cutting tool path during surface high-speed machining by the proposed method.

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