A discrete simulation-based algorithm for the technological investigation of 2.5D milling operations

2018 ◽  
Vol 233 (1) ◽  
pp. 78-90 ◽  
Author(s):  
Adam Jacso ◽  
Tibor Szalay ◽  
Juan Carlos Jauregui ◽  
Juvenal Rodriguez Resendiz
Keyword(s):  
Tool Path ◽  
Analytical Description ◽  
Machining Process ◽  
Simulation Algorithm ◽  
Tool Paths ◽  
Milling Operations ◽  
Nc Simulation ◽  
2.5D Milling ◽  
Milling Tool ◽  
Nc Milling

Many applications are available for the syntactic and semantic verification of NC milling tool paths in simulation environments. However, these solutions – similar to the conventional tool path generation methods – are generally based on geometric considerations, and for that reason they cannot address varying cutting conditions. This paper introduces a new application of a simulation algorithm that is capable of producing all the necessary geometric information about the machining process in question for the purpose of further technological analysis. For performing such an analysis, an image space-based NC simulation algorithm is recommended, since in the case of complex tool paths it is impossible to provide an analytical description of the process of material removal. The information obtained from the simulation can be used not only for simple analyses, but also for optimisation purposes with a view to increasing machining efficiency.

scholarly journals 5-Axis Flank Milling Tool Path Smoothing Based on Kinematical Behaviour Analysis

2011 ◽  
Vol 223 ◽  
pp. 691-700 ◽  
Author(s):  
Xavier Beudaert ◽  
Pierre Yves Pechard ◽  
Christophe Tournier
Keyword(s):  
Tool Path ◽  
Maximum Velocity ◽  
Flank Milling ◽  
Machining Time ◽  
Machined Surface ◽  
Tool Paths ◽  
Area Of Interest ◽  
Milling Tool ◽  
Joint Coordinates ◽  
Kinematical Behaviour

In the context of 5-axis flank milling, the machining of non-developable ruled surfaces may lead to complex tool paths to minimize undercut and overcut. The curvature characteristics of these tool paths generate slowdowns affecting the machining time and the quality of the machined surface. The tool path has to be as smooth as possible while respecting the maximum allowed tolerance. In this paper, an iterative approach is proposed to smooth an initial tool path. An indicator of the maximum feedrate is computed using the kinematical constraints of the considered machine tool, especially the maximum velocity, acceleration and jerk. Then, joint coordinates of the tool path are locally smoothed in order to raise the effective feedrate in the area of interest. Machining simulation based on a N-buffer algorithm is used to control undercut and overcut. This method has been tested in flank milling of an impeller and can be applied in 3 to 5-axis machining.

An Algorithm for Geometric Modeling and Intersection in NC Milling Simulation Based on Triangular Mesh Model

2011 ◽  
Vol 48-49 ◽  
pp. 541-546 ◽  
Author(s):  
Dian Zhu Sun ◽  
Xin Cai Kang ◽  
Yan Rui Li ◽  
Yong Wei Sun
Keyword(s):  
Geometric Modeling ◽  
Tool Path ◽  
Triangular Mesh ◽  
Simulation Process ◽  
Mesh Model ◽  
Milling Simulation ◽  
Nc Simulation ◽  
Simulation Based ◽  
Triangular Mesh Model ◽  
Nc Milling

To achieve the accurate and efficient NC milling simulation based on the discrete triangular mesh model, we proposed an algorithm for geometric modeling and intersection. We construct the R*-tree index for upper-surface nodes of mesh model, based on which the nodes within cutting region can be obtained. We compute tool path segments within cutting projection region of node, and calculate the minimum adjustment height of node according to tool path segments within cutting projection region and then change the z-value of node. Thus, we complete the intersection calculation in simulation process. It has been proved by examples that the algorithm for geometric modeling and intersection in NC milling simulation has strong adaptation to tool path segment type and that it can accurately and efficiently reflect the effect of NC simulation process based on the discrete triangular mesh model of rough.

Tool Path Generation for Turbine Blades Machining With Twin Tool

2017 ◽  
Vol 139 (11) ◽  
Author(s):  
Dun Lu ◽  
Jun Liu ◽  
Wanhua Zhao ◽  
Bingheng Lu ◽  
Diaodiao Wu ◽  
...  
Keyword(s):  
Cutting Forces ◽  
Nuclear Power ◽  
Tool Path ◽  
Contact Point ◽  
Turbine Blades ◽  
Machining Process ◽  
Element Analysis ◽  
Machining Precision ◽  
Tool Paths ◽  
Geometric Precision

Blades are essential parts used in thermal and nuclear power generation. Its machining precision is a vital factor that influences the efficiency and life of those industries. Blades are thin-walled parts, which could easily deform under cutting forces, and hence deteriorate the machining precision. In our previous work, a milling process with twin tool for blade is proposed, in which two tools are assigned to machine the basin and dorsal surfaces simultaneously. It is expected that the cutting forces acted on the basin and dorsal surfaces can be counteracted to reduce the deformation of the blade. In this study, a method of twin-tool paths generation is developed. The tool center points and tool axis vectors are generated with consideration of the cutting forces balance, the machine tool kinematics, the surface geometric precision, and the same number of tool paths on basin and dorsal surfaces. Virtual machining, finite element analysis, and trial cutting are carried out and verified that the method which is used for generating the twin-tool paths is successful. The basin and dorsal surfaces have the same number of tool paths and tool contact point coordinates, which guarantees that the two surfaces can be completely machined and can be machined and finished simultaneously. Furthermore, the cutting forces acted on the basin and dorsal surfaces can achieve the balance along the twin-tool paths. Therefore, the deformation of a blade caused by cutting force is obviously reduced compared with a conventional machining process with a single tool.

Research on Five-Axis CNC Machining Simulation and Experiment of Integrated Impeller Based on VERICUT

2013 ◽  
Vol 670 ◽  
pp. 119-122
Author(s):  
W.G. Du ◽  
Y.Y. Guo ◽  
C. Zhao
Keyword(s):  
Tool Path ◽  
Simulation Software ◽  
Cnc Machining ◽  
Machining Process ◽  
Simulation Platform ◽  
Machining Simulation ◽  
Data Simulation ◽  
Interference Phenomenon ◽  
Nc Simulation ◽  
Five Axis

Machining with five-axis equipment can offer manufactures many advantages, including dramatically reduced setup times, lower costs per part, more accurate machining and improved part quality. While in five-axis machining, the tool axis changes frequently, even the most experienced engineers are difficult to judge the correctness of its tool path. So in this paper, taking five-axis machine tools as the prototype, the process of building NC simulation platform was introduced by using simulation software VERICUT. After that, it introduced simulation operations, verifying the simulation platform and data simulation function. Finally, the correctness of the simulation was verified by machining experiments. Researching CNC machining process on the VERICUT platform, the research results were used in five-axis machining simulation of integrated impeller and it improved both the process capacity and efficiency of the integrated impeller greatly. This method obtained in this paper could eliminate the colliding and interference phenomenon during test cut, reduce costs, improve the efficiency of programming and shorten the manufacturing period.

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.

Nonparametric Tool Path Compensation for Machining Flexible Parts

2016 ◽  
Author(s):  
Waku Hatakeyama ◽  
Cong Wang ◽  
Lu Lu
Keyword(s):  
Tool Path ◽  
Gaussian Process Regression ◽  
Experimental Tests ◽  
Machining Process ◽  
Physical Parameters ◽  
Tool Paths ◽  
Nonparametric Learning ◽  
Compensation Methods ◽  
Flexible Parts ◽  
Physical Information

This paper discusses the compensation of tool paths for machining flexible parts. Despite various research published on the topic, machining in practice nowadays remains limited to tool path planning based on only the geometric models of the parts and tools. This is mainly because that tool path compensation methods usually require accurate physical information of the systems and rely on analytical or finite element simulations, which are often not available to the end-users. In regards to this problem, this paper presents data-oriented nonparametric learning methods that require solely the geometric measurements of the trial machined contour(s). The physical parameters of the parts and tools as well as simulations of the machining process are not required. Two algorithms are developed based on Gaussian Process Regression and Artificial Neural Network respectively. Experimental tests are conducted. A plan of further improving the results using an auxiliary real-time vision sensor is also discussed.

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