D34 Tool Path Modification for Overlapping Part of Tool Entry and Exit in End Milling

2010 ◽  
Vol 2010.8 (0) ◽  
pp. 253-254
Author(s):  
Tomoya KUDO ◽  
Soichi IBARAKI ◽  
Atsushi MATSUBARA
Keyword(s):  
Tool Path ◽  
End Milling ◽  
Entry And Exit ◽  
Path Modification ◽  
Tool Path Modification

scholarly journals Machining Time Reduction by Tool Path Modification to Eliminate Air Cutting Motion for End Milling Operation

2020 ◽  
Vol 14 (3) ◽  
pp. 459-466 ◽  
Author(s):  
Isamu Nishida ◽  
◽  
Keiichi Shirase
Keyword(s):  
Tool Path ◽  
End Milling ◽  
Axial Direction ◽  
Contour Line ◽  
Product Model ◽  
Machining Time ◽  
High Productivity ◽  
Product Surface ◽  
Path Modification ◽  
Tool Path Modification

A method to uniquely calculate the tool path and to modify the tool path during air cutting motion to reduce the machining time is proposed. This study presents a contour line model, in which the product model is minutely divided on a plane along an axial direction, and the contour line of the cross-section of the product is superimposed. A method is then proposed to calculate the tool position according to the degree of interference between the product surface and the tool. Furthermore, this study proposes a technique to reduce the machining time by tool path modification during air cutting motion. This is determined by the geometric relationship between the product surface and the tool, and not based on cutting simulations. A cutting experiment was conducted to validate the effectiveness of the proposed method. Based on the results, it was confirmed that the difference in machining time between the tool path with modification and the tool path without modification was large. Moreover, the machining time was significantly reduced by the tool path modification. The results showed that the proposed method has good potential to perform customized manufacturing, and to realize both high productivity and reliability in machining operation.

A Tool Path Modification Approach to Cutting Engagement Regulation for the Improvement of Machining Accuracy in 2D Milling With a Straight End Mill

2007 ◽  
Vol 129 (6) ◽  
pp. 1069-1079 ◽  
Author(s):  
M. Sharif Uddin ◽  
Soichi Ibaraki ◽  
Atsushi Matsubara ◽  
Susumu Nishida ◽  
Yoshiaki Kakino
Keyword(s):  
Cutting Force ◽  
Case Studies ◽  
Tool Path ◽  
Free Form ◽  
Geometric Accuracy ◽  
End Mill ◽  
Workpiece Surface ◽  
Engagement Angle ◽  
Path Modification ◽  
Tool Path Modification

In two-dimensional (2D) free-form contour machining by using a straight (flat) end mill, conventional contour parallel paths offer varying cutting engagement with workpiece, which inevitably causes the variation in cutting loads on the tool, resulting in geometric inaccuracy of the machined workpiece surface. This paper presents an algorithm to generate a new offset tool path, such that the cutting engagement is regulated at a desired level over the finishing path. The key idea of the proposed algorithm is that the semi-finish path, the path prior to the finishing path, is modified such that the workpiece surface generated by the semi-finish path gives the desired engagement angle over the finishing path. The expectation with the proposed algorithm is that by regulating the cutting engagement angle along the tool path trajectory, the cutting force can be controlled at any desirable value, which will potentially reduce variation of tool deflection, thus improving geometric accuracy of machined workpiece. In this study, two case studies for 2D contiguous end milling operations with a straight end mill are shown to demonstrate the capability of the proposed algorithm for tool path modification to regulate the cutting engagement. Machining results obtained in both case studies reveal far reduced variation of cutting force, and thus, the improved geometric accuracy of the machined workpiece contour.

scholarly journals Minimizing Flute Engagement to Adjust Tool Orientation for Reducing Surface Errors in Five-Axis Ball End Milling Operations

2020 ◽  
Vol 143 (2) ◽  
Author(s):  
M. Habibi ◽  
Z. M. Kilic ◽  
Y. Altintas
Keyword(s):  
Optimization Problem ◽  
Tool Path ◽  
End Milling ◽  
Contact Point ◽  
Geometrical Approach ◽  
Tool Orientation ◽  
Ball End Milling ◽  
Surface Errors ◽  
Five Axis ◽  
Path Modification

Abstract Surface errors due to force-induced tool and workpiece deflections are one of the major errors in multi-axis machining of parts especially with thin-walled structures. Dominant approaches to reduce these surface errors are re-machining the part, feed scheduling, and tool path modification. These methods are time consuming and computationally costly, and they rely on experimental data which is used in cutting force and deflection predictions. The present paper introduces a pure geometrical approach to reduce surface errors drastically by minimizing the engagement lengths of flutes’ cutting edges when a point on the flute’s cutting edge is in contact with the design surface. The total engagement length of the flutes’ cutting edges when one of them generates a contact point on the workpiece surface is formulated and considered as the minimization objective function of an optimization problem. Tilt and lead angles, which define the tool orientation, are the design variables of the optimization problem subjected to constraints based on the geometrical requirements of the ball end milling process. The optimization problem uses the nominal tool path to generate an optimal tool path with adjusted tool orientations. The presented method is computationally inexpensive and does not need any experimentally calibrated coefficients to predict cutting forces because of the pure geometrical nature of the approach. The method is experimentally validated through five-axis ball end milling experiments in which more than 90% surface error reduction is achieved.

Parameter Optimization of Ball End Milling Process on Inconel 718 Using RSM and TLBO Algorithm

2015 ◽  
Vol 15 (3) ◽  
pp. 293-300 ◽  
Author(s):  
Nandkumar N. Bhopale ◽  
Nilesh Nikam ◽  
Raju S. Pawade
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Tool Path ◽  
End Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Ball End Milling

AbstractThis paper presents the application of Response Surface Methodology (RSM) coupled with Teaching Learning Based Optimization Technique (TLBO) for optimizing surface integrity of thin cantilever type Inconel 718 workpiece in ball end milling. The machining and tool related parameters like spindle speed, milling feed, axial depth of cut and tool path orientation are optimized with considerations of multiple response like deflection, surface roughness, and micro hardness of plate. Mathematical relationship between process parameters and deflection, surface roughness and microhardness are found out by using response surface methodology. It is observed that after optimizing the process that at the spindle speed of 2,000 rpm, feed 0.05 mm/tooth/rev, plate thickness of 5.5 mm and 15° workpiece inclination with horizontal tool path gives favorable surface integrity.

Micro Flat End Milling Simulation Model With Instantaneous Plowing Area Prediction

2016 ◽  
Vol 4 (2) ◽  
Author(s):  
Abdolreza Bayesteh ◽  
Junghyuk Ko ◽  
Martin Byung-Guk Jun
Keyword(s):  
Feed Rate ◽  
Tool Path ◽  
End Milling ◽  
Chip Thickness ◽  
Depth Of Cut ◽  
Uncut Chip Thickness ◽  
Chip Area ◽  
Edge Radius ◽  
Wide Range ◽  
Radial Depth

There is an increasing demand for product miniaturization and parts with features as low as few microns. Micromilling is one of the promising methods to fabricate miniature parts in a wide range of sectors including biomedical, electronic, and aerospace. Due to the large edge radius relative to uncut chip thickness, plowing is a dominant cutting mechanism in micromilling for low feed rates and has adverse effects on the surface quality, and thus, for a given tool path, it is important to be able to predict the amount of plowing. This paper presents a new method to calculate plowing volume for a given tool path in micromilling. For an incremental feed rate movement of a micro end mill along a given tool path, the uncut chip thickness at a given feed rate is determined, and based on the minimum chip thickness value compared to the uncut chip thickness, the areas of plowing and shearing are calculated. The workpiece is represented by a dual-Dexel model, and the simulation properties are initialized with real cutting parameters. During real-time simulation, the plowed volume is calculated using the algorithm developed. The simulated chip area results are qualitatively compared with measured resultant forces for verification of the model and using the model, effects of cutting conditions such as feed rate, edge radius, and radial depth of cut on the amount of shearing and plowing are investigated.

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