Development of Tool Path Generation Method for Complex Deep Groove Shape With Simultaneous 4-Axis Machining

2020 ◽  
Author(s):  
Kohei Ichikawa ◽  
Takayuki Nakamura ◽  
Jun'ichi Kaneko ◽  
Masanobu Hasegawa ◽  
Takeyuki Abe
Keyword(s):  
Tool Path ◽  
Complex Surface ◽  
Process Efficiency ◽  
Rotational Axis ◽  
Feed Speed ◽  
Groove Shape ◽  
Deep Groove ◽  
Complex Shapes ◽  
Tool Posture ◽  
Improved Performance

Abstract In recent years, aero engine parts with complex shapes are increasing due to demand on improved performance and weight reduction. In one example, some of those parts have groove which are deep, narrow and complex surface. They are processed by Simultaneous 5-axis machining with small ball end-mill. However, its complex groove shape cause greatly move of tool posture, thereby it cause greatly and discontinuous move of rotational and tilting axis of machine tool. As a result, actual feed speed cannot follow the commanded feed speed, so low process efficiency is problem. It can be considered simultaneous 4-axis machining which with fixed tilting axis as countermeasure. However it is difficult to generating tool path of simultaneous 4-axis machining by commercial Computer Aided Manufacturing (CAM) software for these deep groove shapes because of its tool collision avoidance algorithm. In this study, we developed method of generating tool path that can be machining simultaneous 4-axis machining while avoiding collision of workpiece and tool as an aim of increasing process efficiency. Furthermore, In order to effect of further improve the feed speed, we studied about posture planning way with possible to continuous moving of rotational axis, and we conducted verification test of increasing of feed speed with proposed method.

Optimization Method of Rotational Axis Motion in 5-Axis Controlled Machining to Keep Command Tool Feed Rate

2020 ◽  
Author(s):  
Takayuki Nakamura ◽  
Kohei Ichikawa ◽  
Masanobu Hasegawa ◽  
Jun'ichi Kaneko ◽  
Takeyuki Abe
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Machining Process ◽  
Rotational Axis ◽  
Feed Speed ◽  
Machining Processes ◽  
Machining Time ◽  
Machined Surface ◽  
Lead Angle ◽  
Tool Posture

Abstract In recent machining processes, 5-axis controlled machine tool is widely used for machining complicated workpiece shape with curved surface. In such process, to achieve high productivity, planning method of cutting conditions to satisfy both following the commanded tool feed rate in machining process and realization of good surface roughness are required. In conventional study, it is known that lead angle of tool posture against local machined surface influence the surface roughness. Then, common commercial CAM systems have already functioned to avoid interference and control the lead angle in each cutter location. However, in the generated cutter locations by the conventional algorithms, when the tool posture changes rapidly, there is a problem that actual feed rate does not reach the command value and machining time becomes longer than expected. In this paper, we propose the new tool posture correction algorithm. In the proposed method, first, the rotational axis that causes the feed speed rate decline is specified by preliminary experiments. And, the jerk value that is the threshold for the feed speed decline is investigated. After that, for the NC program, the command value of the target axis is modified within a range where interference of cutting tool does not occur, thereby preventing a decline in the actual feed rate. This paper describes an outline of the proposed modification method and the effect of the modification of the target axis positions on the lead angle and the actual feed rate.

Tool Motion Control Referring to Voxel Information of Removal Volume Voxel Model to Achieve Autonomous Milling Operation

2014 ◽  
Vol 8 (6) ◽  
pp. 792-800 ◽  
Author(s):  
Tomokazu Kobayashi ◽  
◽  
Toshihiko Hirooka ◽  
Atsushi Hakotani ◽  
Ryuta Sato ◽  
...  
Keyword(s):  
Diffusion Equation ◽  
Motion Control ◽  
Tool Path ◽  
Control Function ◽  
Feed Speed ◽  
Milling Operation ◽  
Tool Posture ◽  
Voxel Model ◽  
Copy Milling ◽  
Tool Motion

In order to achieve flexible and autonomous milling operation, a system called Digital Copy Milling (DCM) was developed in our previous studies. Additionally, tool motion control, in which the voxel information of the removal volume voxel model is referred to, is performed in DCM. In this study, a feed speed control function and tool posture control function are integrated with the DCM by referring to the feed speed and tool posture parameters stored in the voxel properties of the removal volume voxel model. It is assumed that these parameters change gradually as a diffusion phenomenon to automatically determine the voxel properties using a diffusion equation. In order to calculate the diffusion equation, the voxel in the removal volume corresponds to a calculation grid of the diffusion equation and not just to the storage of the feed speed and tool posture parameters. For experimental verification, the feed speed and tool posture parameters were automatically determined, and the tool motion was successfully controlled independent of the tool path generation to perform the milling operation.

Method of Planning Tool Postures for Deep Groove Machining of Complex Shapes – Development of an Automatic Planning Method that Considers the Motions of the Rotational Axis when the Tool Reverses Direction in Grooved Shapes –

2017 ◽  
Vol 11 (2) ◽  
pp. 226-234 ◽  
Author(s):  
Kohei Ichikawa ◽  
◽  
Jun’ichi Kaneko ◽  
Masanobu Hasegawa ◽  
Takayuki Iwasaki ◽  
...  
Keyword(s):  
Planning Method ◽  
Coordinate Space ◽  
Rotational Axis ◽  
Planning Tool ◽  
Axis Of Rotation ◽  
Deep Groove ◽  
Complex Shapes ◽  
Automatic Planning ◽  
Machined Surfaces

Simultaneous 5-axis control machining is used to machine components in complex, deep grooved shapes. In order to maintain actual feed rates in this kind of machining, it is vitally important to secure continuity in the movement of the rotational axis. When the tool reverses its direction of travel, however, its axis of rotation is liable to make sudden movements. In this study, therefore, we first derive candidate tool postures that can meet the conditions for relative postures to machined surfaces while avoiding tool interferences. We then develop a method for automatically planning continuous changes in the command values of the rotating axial angles in the machine coordinate space.

Development of Multi-Axis Laser-Assisted Milling Device

2017 ◽  
Author(s):  
Dong-Hyeon Kim ◽  
Wan-Sik Woo ◽  
Won-Shik Chu ◽  
Sung-Hoon Ahn ◽  
Choon-Man Lee
Keyword(s):  
Heat Source ◽  
Tool Path ◽  
Cutting Tool ◽  
Field Studies ◽  
Flat Surfaces ◽  
Laser Heat ◽  
Complex Shapes ◽  
Laser Heat Source ◽  
Removal Processes ◽  
Machining Productivity

Laser-assisted machining (LAM) process is an effective method to facilitate material removal processes for difficult-to-cut materials. In LAM process, the mechanical strength of various materials is reduced by a laser heat source focused in front of the cutting tool during machining. Since the laser heat source is located ahead of the cutting tool, the workpiece is preheated by the heat source. This enables difficult-to-cut materials to be machined more easily with low cutting energy, increasing the machining productivity and accuracy. It is difficult to apply laser-assisted milling (LAMilling) to workpieces having complex shapes, because it is not easy to control laser preheating and the cutting tool path for three-dimensionally shaped workpieces. LAMilling has only been used in limited fields such as single-direction machining of flat surfaces. To apply this process in the industrial field, studies on workpieces having various shapes are needed. This study aims to develop a laser-assisted milling device having multiple axes and to investigate the machining characteristics of several difficult-to-cut materials.

Development of Embedded Linux CNC System Based on ARM9

2011 ◽  
Vol 467-469 ◽  
pp. 906-911 ◽  
Author(s):  
Shu Kun Cao ◽  
Chang Lei Wang ◽  
Hui Zhang ◽  
Jie Lv ◽  
Chang Zhong Wu
Keyword(s):  
Tool Path ◽  
Free Form ◽  
Cnc System ◽  
Open Cnc ◽  
Standard Interface ◽  
Stepper Motors ◽  
Tool Posture ◽  
Cross Platform ◽  
Five Axis ◽  
The Way

Five-axis machining area of free surface is proposed by based on ARM9 and Linux open CNC system's overall structure of the CNC system hardware and software architecture. The system adopts the mode of the host computer PC, the lower computer ARM9 development board. PC completes the model of space surface and generates tool path by Simultaneous Multi-objective Optimization Algorithm on Free-form Surface Five-Axis Machining Tool Path and Tool Posture. The lower computer applies MYSQL database to storage and manage cutter location point information. Other modules access the database through ODBC standard interface. ARM9and PC utilize the way of cross-platform socket data transmission, the stepper motors is controlled by the way of constant acceleration - deceleration.

scholarly journals A Highlight-Generation Method for Rendering Translucent Objects

Sensors ◽  
2019 ◽  
Vol 19 (4) ◽  
pp. 860 ◽  
Author(s):  
Hui Yu ◽  
Peter Liu ◽  
Lingyan Hu
Keyword(s):  
Complex Surface ◽  
Orthonormal Frame ◽  
Bidirectional Reflectance Distribution Function ◽  
Surface Geometry ◽  
Subsurface Scattering ◽  
Bidirectional Reflectance ◽  
Local Orthonormal Frame ◽  
Common Task ◽  
Complex Shapes ◽  
Bidirectional Reflectance Distribution

The acquisition of translucent objects has become a very common task thanks to the progress of 3D scanning technology. Since the characteristic soft appearance of translucent objects is due to subsurface scattering, the details are naturally left out in this appearance. For objects that have complex shapes, this lack of detail is obviously more prominent. In this paper, we propose a method to preserve the details of surface geometry by adding highlight effects. In generating highlight effects, our method employs a local orthonormal frame and combines, in a novel way, the incoming and outgoing light in approximating the subsurface scattering process. When the incident illuminant direction changes from nearly overhead to nearly horizontal, our method effectively preserves complex surface geometry details in the appearance of translucent materials. Through experiments, we show that our method can store surface features as well as maintain the translucency of the original materials and even enhance the perception of translucency. By numerically comparing the generated highlight effects with those generated by the traditional Bidirectional Reflectance Distribution Function (BRDF) models with different bandwidth parameters, we demonstrate the validity of our proposed method.

Cutter Path Optimization during High-Speed Machining of Numerical Control

2011 ◽  
Vol 341-342 ◽  
pp. 318-322
Author(s):  
Yong Xiang Gao
Keyword(s):  
High Speed ◽  
Numerical Control ◽  
Process Efficiency ◽  
Feed Speed ◽  
High Speed Machining ◽  
Cutting Depth ◽  
Curvature Variation ◽  
Cutter Path ◽  
Feed Mode ◽  
Path Curvature

During the high-speed machining, cutter path of numerical control needs to satisfy the following requirements. There has no colliding among work pieces, fixtures and so on. The cutter path variation cannot too dramatically and the vibration should in the controlled area during the process. Feed speed can modify with path curvature variation and cutting depth need to be equality. This article will analyze and research in the mode of cutter advanced and retreats, cutter movement mode, cutter feed mode and cutter path of corner treatment during the high-speed process programming that could effective optimize cutter path, process efficiency and quality.

Tool Posture Optimization Subjected to the Rigidity of Multi-Axis Machine Tool

2008 ◽  
Vol 392-394 ◽  
pp. 271-277
Author(s):  
R. Yan ◽  
F.Y. Peng ◽  
J.Z. Yang ◽  
Bin Lin
Keyword(s):  
Product Quality ◽  
Control Strategy ◽  
Three Dimensional ◽  
Complex Surface ◽  
Posture Control ◽  
Stiffness Index ◽  
Sculptured Surface ◽  
Tool Posture ◽  
Machining Planning ◽  
Local Stiffness

In order to achieve higher product quality for sculptured surface productions, an advanced strategy are proposed for machining planning, namely a tool-posture-control strategy. In the tool-posture-control strategy, machining chatter is reduced by controlling the machine rigidity along cutting feed direction. This proposed strategy, which improved product quality of sculptured surface when subjected to both the part geometry and the machine rigidity constrains, is described in this paper. A new machining-planning aid called local stiffness index is developed to help tool posture planning. This proposed strategy subjected to multi-constrains help a part programmer to choice the optimum tool posture. In order to illustrate the application of stiffness index map and the proposed strategy, the applications of the proposed strategy to real three-dimensional complex surface (e.g. a turbine blade) are presented in this paper.

Method for Feed-Rate Optimization Based on S Curve Acceleration and Deceleration Control of Piecewise Tool Path

2012 ◽  
Vol 542-543 ◽  
pp. 551-554
Author(s):  
Xiao Bing Chen ◽  
Wen He Liao
Keyword(s):  
Feed Rate ◽  
Tool Path ◽  
Complex Surface ◽  
Experimental Result ◽  
Threshold Method ◽  
Lower Efficiency ◽  
Acceleration And Deceleration ◽  
S Curve ◽  
Rate Optimization ◽  
Feed Rate Optimization

Aiming at the problem of lower efficiency of complex surface machining with constant feed-rate, a method for feed-rate optimization based on S curve acceleration and deceleration control of piecewise tool path is researched. With constraints of kinematic characters of machine tool and geometric characters of tool path, tool path segments are obtained by curvature threshold method, and feed-rates are planned in these segments, then feed-rate transition of adjacent segments is processed by the method of S curve acceleration and deceleration control. Experimental result indicates that the proposed method is feasible and effective.

Compensating Cleanup Tool Path

1998 ◽  
Author(s):  
Xiaohong Zhu ◽  
Richard F. Riesenfeld
Keyword(s):  
Tool Path ◽  
Machining Process ◽  
Process Efficiency ◽  
Shop Floor ◽  
Machining Time ◽  
Motion Constraints ◽  
Tool Paths ◽  
Cad Cam ◽  
Computationally Intensive ◽  
Increase Tool Life

Abstract Today’s part geometries are becoming ever more complex and require more accurate tool path to manufacture. Machining process efficiency is also a major consideration for designers as well as manufacturing engineers. Although the current advanced CAD/CAM systems have greatly improved the efficiency and accuracy of machining with the introduction of Numerically–Controlled machining, excessive material may still be left on the finished part due to machining constraints, including the inaccessibility of the designed part geometry with respect the cutter, machine motion constraints like ramp angles, specific cutting patterns, etc. Polishing operations such as grinding and hand finishing are quite time consuming and expensive, and may damage the surface of the part or introduce inaccuracies because of human errors. While most of the existing machining approaches attempt to reduce such excessive restmaterials by modifying NC tool paths, none of them is satisfactory. They can be time–consuming, error prone, computationally intensive, too complicated to implement, and limited to certain problem domains. A compensating cleanup tool path will be developed in this research to automatically remove these excessive material from the finish part. This method greatly reduces the burden of hand finishing and polishing, and also reduces the error and complexities introduced in manually generating cleanup tool paths in the shop floor. More important, the tool path generated by this method will reduce the machining time, and increase tool life compared with optimized tool path which left no excessive material behind.

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