Tool Path Generation for Five-Axis Controlled Machining of Free-Form Surface Using Barrel Tool: Control of Contact Point on Cutting Edge

Abstract This study aimed to improve the efficiency of free-form surface machining by using a five-axis controlled machine tool and a barrel tool. The barrel tool has cutting edges, with curvature smaller than the radius, increasing the pick feed width compared with a conventional ball end mill of the same tool radius. As a result, the machining efficiency can be improved; however, the cost of the barrel tool is high and difficult to reground. In this study, a method to obtain the cutting points that make the cusp height below the target value is proposed. Moreover, a method to improve the tool life by continuously and uniformly changing the contact point on the cutting edge is proposed. The usefulness of the developed method is confirmed through machining simulations.

Machining of Free-Form Surface Base on Cutter Shaft Tilt Method with Ball-End Cutter

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.215.176 ◽

2011 ◽

Vol 215 ◽

pp. 176-181

Author(s):

Li Min ◽

Ke Hua Zhang

Keyword(s):

Tool Path ◽

Tool Path Generation ◽

Free Form ◽

Real Surface ◽

End Mill ◽

Ball End Mill ◽

Surface Machining ◽

Processing Accuracy ◽

Free Form Surface ◽

A new tool path generation method based on cutter shaft tilt method was proposed for free-form surface machining by using Ball-end Cutter. Firstly, it introduces the processing quality problems caused by traditional ball-end mill processing. Then cutter shaft tilt was proposed to avoid the above questions. Analyzing the different machining efficiency at the different angle, and then cutter shaft tilt compensation method which based on above method could avoid that problem was proposed. After the paths calculation to a real surface and simulation, the result shows that, comparing to traditional machining method, the new method reduced efficiently phenomenon of extruding and scratching surface. It meets five-axis processing accuracy requirements.

Machining of Free-Form Surface Method and Implementation Research with Ball-End Cutter

Materials Science Forum ◽

10.4028/www.scientific.net/msf.697-698.244 ◽

2011 ◽

Vol 697-698 ◽

pp. 244-248

Author(s):

Ke Hua Zhang ◽

Li Min ◽

Dong Hui Wen

Keyword(s):

Tool Path ◽

Computer Hardware ◽

Free Form ◽

Machining Accuracy ◽

End Mill ◽

Ball End Mill ◽

Surface Machining ◽

Free Form Surface ◽

Tool Position ◽

A new tool path generation method based on Z-buffer method is proposed for free-form surface machining by using ball-end cutters. Firstly, to avoid ball-end mill cutting the workpiece, we make the cutter shaft which is perpendicular to machining surface tilt angle θ, then determine the examining area and then judge there is or not a interference occurring between ball-end mill and examining area, if there is, then make a adjustment for cutter shaft. The discretized points within the examining area are efficiently read in and stored directly by the computer hardware; no extra searching and iterative methods are needed. Simulation results show that, comparing with the traditional algorithm, the tool-position calculation time is shorter, and the phenomenon of workpiece squeezed and scratched is less in this algorithm. It meets the basic needs of five axis machining accuracy. Finally we make a practical machining experiment for cutter location generated.

The strategy of sequential surface machining of the free form surface with the use the ball-end mill and elastic abrasive discs

Mechanik ◽

10.17814/mechanik.2016.8-9.258 ◽

2016 ◽

pp. 1082-1083

Author(s):

Jarosław Plichta ◽

Jan Baran

Keyword(s):

Free Form ◽

End Mill ◽

Ball End Mill ◽

Surface Machining ◽

Free-Form Surface Five-Axis Machining Tool Path and Tool Posture Simultaneous Multi-Objective Optimization Theory Research

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.467-469.900 ◽

2011 ◽

Vol 467-469 ◽

pp. 900-905

Author(s):

Shu Kun Cao ◽

Li Song ◽

Kai Feng Song ◽

Jie Lv ◽

Xiu Sheng Chen

Keyword(s):

Tool Path ◽

Contact Point ◽

Free Form ◽

Multi Objective Optimization ◽

Scallop Height ◽

Multi Objective ◽

Tool Axis ◽

Tool Posture ◽

Free Form Surface ◽

In view of all sorts of questions existing in CNC machining, such as machining vibration, so proposed a new simultaneous multi-objective optimization algorithm on free-form surface five-axis machining tool path and tool posture based on constant scallop height. In the algorithm, we first complete the surface fitting on the base of feature points obtained. Secondly calculate principal curvatures of the surface, select tools, and at the same time generate tool axis vector in the current cutter-contact point tool axis. Once again get the maximum spacing and surface curvature in accordance with the tool effective cutting radius, discrete into cutter-contact point, and calculate the cutting depth to adjust the machine feed rate. And finally connect adjacent curve path using the diagonal to achieve a continuous cutting scallop height tool path. This algorithm can achieve the goals such as the same precision, improving processing efficiency, reducing the number of tool cutting in and out, reducing cutting vibration and tool wear and so on. That is the algorithm can achieve simultaneous multi-objective optimization of the free-form surface NC machining finally.

A High-Efficiency Impeller Channel Quasi-Triangular Tool Path Planning Method Based on Template Trajectory Mapping

Xibei Gongye Daxue Xuebao/Journal of Northwestern Polytechnical University ◽

10.1051/jnwpu/20183661216 ◽

2018 ◽

Vol 36 (6) ◽

pp. 1216-1223

Author(s):

Feiyan Han ◽

Juan Wei ◽

Bin Feng ◽

Wu Zhang

Keyword(s):

Path Planning ◽

Tool Path ◽

Planning Method ◽

Free Form ◽

Physical Domain ◽

Tool Path Planning ◽

Surface Machining ◽

Mapping Model ◽

Trajectory Mapping ◽

The manufacturing technology of an integral impeller is an important indicator for measuring the manufacturing capability of a country. Its manufacturing process involves complex free-form surface machining, a time consuming and error-prone process, and the tool path planning is considered as a critical issue of free-form surface machining but still lacks a systematic solution. In this paper, aiming at the tool path planning of the impeller channel, a quasi-triangular tool path planning method based on parametric domain template trajectory mapping is proposed. The main idea is to map the template trajectory to physical domain by using the mapping model of parametric domain to the physical domain to obtain the actual machining path. Firstly, the trajectory mapping model of parametric domain to physical domain is established using the morphing technique, and the template trajectory mapping method in the parametric domain is given. Secondly, the clean-up boundary of the impeller channel is determined in the parametric domain, and the quasi-triangular template trajectory of the impeller channel is defined. Finally, taking a certain type of impeller as an example, the quasi-triangular tool path of the impeller channel is calculated, and the tool path calculation time of this method is compared with that of the traditional isometric offset method. The result shows that the computational efficiency is improved by 45% with this method, which provides a new method for the rapid acquisition of NC machining tool path for impeller channels. In addition, the simulation and actual machining are carried out, the results show that the shape of actual cutting traces on the surface of the impeller channel is quasi-triangular, showing that this method is effective and feasible.

MODEL ON METHOD OF NC TOOL PATH INTERVAL ESTIMATION FOR FREE-FORM SURFACE MACHINING

Journal of Mechanical Engineering ◽

10.3901/jme.2001.11.036 ◽

2001 ◽

Vol 37 (11) ◽

pp. 36 ◽

Cited By ~ 1

Author(s):

Yan Shan

Keyword(s):

Tool Path ◽

Interval Estimation ◽

Free Form ◽

Surface Machining ◽

Tool Path Interval ◽

Studies on the Algorithm for Five-Axis NC Machining with Triangular Facet Model

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.385-386.726 ◽

2013 ◽

Vol 385-386 ◽

pp. 726-730

Author(s):

Ren Xian Geng ◽

Hou Jun Qi ◽

Xin Pan ◽

Zhi Gang Liu

Keyword(s):

Tool Path ◽

Nc Machining ◽

Surface Shape ◽

Free Form ◽

Cutting Efficiency ◽

Triangular Facet ◽

Constant Scallop Height ◽

Free Form Surface ◽

Five Axis ◽

Facet Model

Using five-axis equipment for NC machining of free-form surface is an effective way to improve machining quality and machining efficiency, the surface shape and the five coordinate of the complexity of the machine tool movement led to its tool path planning technology is difficult. The paper aimed at the five coordinate NC machining of free-form surface and puts forward a five-axis NC machining method based on triangular facet model. The research based on triangular facet model, using constant scallop height method to calculate the step distance and improve the cutting efficiency to a great extent. In the process, tool path is generated, combining with the method of configuration space interference free.

An Intelligent Optimization Approach of Feedrate Scheduling Based on Hybrid Simulation Models

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.392-394.211 ◽

2008 ◽

Vol 392-394 ◽

pp. 211-215

Author(s):

Li Qiang Zhang ◽

Yu Han Wang ◽

Ming Chen

Keyword(s):

Tool Path ◽

Mechanistic Model ◽

Geometric Model ◽

Physical Models ◽

Free Form ◽

Optimization Approach ◽

Machining Processes ◽

Surface Machining ◽

Feedrate Scheduling ◽

In free-form surface machining, it is essential to optimize the feedrate in order to improve the machining efficiency. Conservative constant feedrate values have been mostly used since there was a lack of physical models and optimization tools for the machining processes. The overall goal of this research is the integration of geometric and mechanistic milling models for force prediction and feedrate scheduling for free-form surface machining. For each tool move a geometric model calculates the cutting geometry parameters, then a mechanistic model uses this information with the constraint force to calculate desired feedrates. The feedrate is written into the part program. When the integrated modeling approach was used, it was shown that the machining time can be decreased significantly along the tool path. Production time in machining propeller example was reduced to 35% compared to constant feedrate cases.

5-Axis Control Dexterous Ultraprecision Micromilling of Ruled Surface with Side Cutting Edge

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.516.176 ◽

2012 ◽

Vol 516 ◽

pp. 176-180

Author(s):

Ryo Nishiyama ◽

Keiichi Nakamoto ◽

Tohru Ishida ◽

Yoshimi Takeuchi

Keyword(s):

Tool Path ◽

Tool Path Generation ◽

Ruled Surface ◽

Cutting Edge ◽

Work Piece ◽

End Mill ◽

Ball End Mill ◽

Tool Paths ◽

End Mills ◽

Quality Surface

This study deals with 5-axis control tool path generation to create microshapes dexterously and efficiently, while maintaining quality. Concerning 5-axis control machining, the use of ball end mills is generally employed. However, this method needs a lot of time to obtain high quality surface. To solve this problem, a side cutting edge of the ball end mill is positively utilized with its parallel to the ruled surface. Therefore, a new CAM system is developed to detect the surface to be machined with the side cutting edge, and to generate collision-free tool paths between the tool and the work piece. The effectiveness of the developed CAM system is experimentally confirmed by creating a tiny Möbius ring.