scholarly journals Enabling Advanced CNC Programming with openNC Controllers for HSM Machines Tools

2016 ◽  
Vol 2 (1) ◽  
Author(s):  
Jean-Yves Hascoet ◽  
Matthieu Rauch
Keyword(s):  
High Speed ◽  
Tool Path ◽  
Control Algorithms ◽  
Process Data ◽  
Path Control ◽  
Test Platform ◽  
Cad Cam ◽  
Cnc Programming ◽  
Advanced Tool ◽  
Online Process

AbstractThe manufacturing area has benefited from various progresses over the last decades, such as High Speed Machining (HSM), but CNC programming is still based on dated practices and habits with a segmented unidirectional CAD/CAM/CNC data chain. Decision power is limited at the NC controller stage and online process optimization is difficult. In contrast, advanced programming approaches, such as STEP-NC [9], aim to unify the product/ process data within a consistent environment from design to machining. Hence, openNC controller solutions which allow access to their internal algorithms, have emerged. It is consequently possible to implement new tool path control algorithms that respond directly to the actual machining condition. This paper focuses on the interest of openNC controllers to develop advanced programming approaches forHSMprocesses. Themajor drawbacks of legacy controllers in the implementation of advanced tool path generation methods are discussed and the most significant openNC projects are reviewed. An integrated test platform has been developed. The advanced HSM programming methods enabled by this openNC controller are discussed.

Advanced CNC Programming Methods for Multi-Axis Precision Machining

2013 ◽  
Vol 581 ◽  
pp. 478-484 ◽  
Author(s):  
Sergey N. Grigoriev ◽  
Andrey A. Kutin ◽  
Mikhail Turkin
Keyword(s):  
High Speed ◽  
Tool Path ◽  
Turbine Blades ◽  
Machining Accuracy ◽  
Machining Time ◽  
High Speed Cutting ◽  
Nc Programming ◽  
Custom Made ◽  
Cad Cam ◽  
Cnc Programming

This paper presents a method to simultaneously increase the accuracy and decrease the calculation time for complex tool path programming in multi-axis machining centers. Examples of complex parts requiring such complex tool paths include various kinds of turbine blades, pump-forcing augers, teeth surfaces, etc. It explains the creation of topological structures on the basis of analytical spline curves with floating range definitions. The method for tool path calculation accommodates the specific requirements for multi-axis milling. The algorithms developed are the foundation for the CAD/CAM software that allows for NC programming and machining on 5-axis centers employing any design model. Industrial tests reveal a 70-80% reduction of NC programming time of parts with complex surfaces, reduced machining time of approximately 40-50% using basic high-speed cutting methods and custom-made tools. The advanced methods of NC programming result in substantially increasing machining accuracy.

Development of Real-Time Look-Ahead Methodology Based on Quintic PH Curve with G2 Continuity for High-Speed Machining

2013 ◽  
Vol 464 ◽  
pp. 258-264 ◽  
Author(s):  
Jing Shi ◽  
Qing Zhen Bi ◽  
Yu Han Wang ◽  
Gang Liu
Keyword(s):  
Real Time ◽  
High Speed ◽  
Tool Path ◽  
Approximation Error ◽  
Machining Process ◽  
Transition Curve ◽  
Look Ahead ◽  
Cad Cam ◽  
Feedrate Fluctuation ◽  
Ph Curve

Curving tool paths composed of straight lines, which are often represented as G01 blocks, are still the most widespread format form in the machining process chain of CAD/CAM/CNC. At the junctions between consecutive segments, the tangency and curvature discontinuities may lead to feedrate fluctuation and acceleration oscillation, which would deteriorate the machining efficiency and quality. In this paper, a real-time look-ahead interpolation methodology is proposed, which adopts a curvature-continuous PH curve as a transition to blend corner at the junction of adjacent lines in the tool path. The blending algorithm can guarantee the approximation error exactly, and the control points of the curve can be calculated analytically. On the other hand, the arc length and the curvature of the transition curve, which are important items in speed planning, also have analytical expressions. All the advantages are the guarantee of calculation efficiency during the interpolation. Except for a curvature-continuous tool path, our look-ahead algorithm adopts a speed planning window strategy to achieve a balance between the calculation capabilities and the real-time interpolation requirements. In this window, the corner transition algorithm and speed planning are implemented simultaneously and dynamically during the interpolation. By defining the width of this window, which is actually the number of linear segments contained in this window, can adjust the time consuming of speed planning. Simulation and experiments on our own developed CNC platform are conducted. The results demonstrate the feasibility and efficiency of the proposed algorithms.

A New One-Side Finish Machining Method for Profile of Globoidal Indexing Cam in High Speed

2009 ◽  
Vol 626-627 ◽  
pp. 611-616
Author(s):  
X.F. Tang ◽  
Wei He ◽  
Y.S. Liu
Keyword(s):  
High Speed ◽  
Tool Path ◽  
New Method ◽  
Practical Calculation ◽  
Machined Surface ◽  
Finish Machining ◽  
Cam Mechanism ◽  
Cad Cam ◽  
Meshing Characteristics ◽  
Path Modification

A new one-side finish machining method for the profile of globoidal indexing cam in high speed, which modifies the tool path of traditional enveloping method, was put forward. The new method is useful for overcoming the defects caused by traditional enveloping method, can realize one-side machining of globoidal indexing cam, can improve the machined surface quality and the meshing characteristics of the cam mechanism. The practical calculation formulas of tool path modification is given, which can be used in developing the CAD/CAM software of the globoidal indexing cam. The new method has great practical value.

HSM Strategies of CAD/CAM Systems — Part I Tool Path Generation

2010 ◽  
Vol 426-427 ◽  
pp. 520-524 ◽  
Author(s):  
Song Lin Ding ◽  
John Mo ◽  
D. Yang
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Tool Path ◽  
Tool Path Generation ◽  
Path Generation ◽  
Cnc Machine ◽  
Technical Requirements ◽  
Cad Cam ◽  
High Feed ◽  
Cutting Processes

Owning to the ultra high feed rate and spindle speed, tool path patterns which are less important in conventional metal cutting processes becomes critical in High Speed Machining (HSM). Without an appropriate tool path strategy HSM can not be fully implemented even though the CNC machine has HSM potentials. In practice attentions are usually drawn to advanced hardware components; tool path pattern catering to HSM is often overlooked. This paper introduces the principles of tool path generation for HSM. Essential properties of HSM and its technical requirements on the CAD/CAM system are summarized. The state-of-the-art technologies and practice-oriented tool path generation methodologies are presented.

HSM Strategies of CAD/CAM Systems — Part II Industrial Application

2010 ◽  
Vol 426-427 ◽  
pp. 559-563 ◽  
Author(s):  
Song Lin Ding ◽  
John Mo ◽  
D. Yang
Keyword(s):  
Industrial Application ◽  
High Speed ◽  
Tool Path ◽  
State Of The Art ◽  
High Speed Machining ◽  
Advantages And Disadvantages ◽  
Software Packages ◽  
Cad Cam ◽  
Increasing Demand ◽  
Cam Systems

Over one hundred types of commercial CAD/CAM systems are currently used in various industries. To meet the increasing demand for high speed machining (HSM) from shop floors most of these systems have integrated functions for the generation of HSM tool path. However, the strategies they adopted and the qualities of HSM tool path generated by these packages differ significantly from system to system. This paper reviews the state-of-the-art HSM strategies adopted by industrial CAD/CAM systems. The review is based on sixteen widely used software packages which include both advanced systems and the relatively concise packages. HSM features of each system are summarized; HSM strategies adopted by those systems are presented; the advantages and disadvantages are discussed as well.

Effect of Tool Path Strategies in Pocket Milling of Aluminium Epoxy

2014 ◽  
Vol 903 ◽  
pp. 15-20 ◽  
Author(s):  
Rusdi Mat Song ◽  
Safian Sharif ◽  
Ahmad Yasir Md Said ◽  
Mohd Tanwyn Mohd Khushairi
Keyword(s):  
Computer Aided Design ◽  
High Speed ◽  
Tool Path ◽  
High Speed Steel ◽  
Cutting Parameters ◽  
Cnc Machining ◽  
Numerical Control ◽  
Machining Time ◽  
Pocket Milling ◽  
Cad Cam

Selection of the most suitable tool path strategy is very essential during machining especially in computer aided design and manufacture (CAD/CAM) as well as computer numerical control (CNC) machining. Existence of various tool path strategies to be applied on advanced composite materials such as aluminium epoxy required extensive researches in determining the best combination of tool path and cutting parameters for better machinability performance. Pocket milling of aluminium epoxy specimen via CAD/CAM was conducted in this study to investigate the effect of three types of tool path strategies namely Inward Helical, Outward Helical and Back and Forth. Uncoated high speed steel (HSS-Co8) ball end mill was used throughout the experiments. The machining responses that were evaluated include machining time, tool wear rate, tool life and surface finish of the machined pockets. In general, the effect of tool path strategy was highly significant on the machining responses and results showed that Back and Forth strategy offered the best machinability results when compared to the other strategies.

A Solid-State On-Load Tap Changer for the Power Transformers of 10—0.4 kV Distribution Networks

Vestnik MEI ◽  
2020 ◽  
Vol 6 (6) ◽  
pp. 82-90
Author(s):  
Dmitriy I. Panfilov ◽  
◽  
Mikhail G. Astashev ◽  
Aleksandr V. Gorchakov ◽  
◽  
...  
Keyword(s):  
Solid State ◽  
Physical Model ◽  
High Speed ◽  
Power Transformer ◽  
Voltage Control ◽  
Power Transformers ◽  
Control Algorithms ◽  
Load Voltage ◽  
Tap Changer ◽  
Load Tap Changer

The specific features relating to voltage control of power transformers at distribution network transformer substations are considered. An approach to implementing high-speed on-load voltage control of serially produced 10/0.4 kV power transformers by using a solid-state on-load tap changer (SOLTC) is presented. An example of the SOLTC circuit solution on the basis of thyristor switches is given. On-load voltage control algorithms for power transformers equipped with SOLTC that ensure high reliability and high-speed operation are proposed. The SOLTC performance and the operability of the suggested voltage control algorithms were studied by simulation in the Matlab/Simulink environment and by experiments on the SOLTC physical model. The structure and peculiarities of the used simulation Matlab model are described. The SOLTC physical model design and its parameters are presented. The results obtained from the simulating the SOLTC operation on the Matlab model and from the experiments on the SOLTS physical model jointly with a power transformer under different loads and with using different control algorithms are given. An analysis of the experimental study results has shown the soundness of the adopted technical solutions. It has been demonstrated that the use of an SOLTC ensures high-speed voltage control, high efficiency and reliability of its operation, and arcless switching of the power transformer regulating taps without load voltage and current interruption. By using the SOLTC operation algorithms it is possible to perform individual phase voltage regulation in a three-phase 0.4 kV distribution network. The possibility of integrating SOLTC control and diagnostic facilities into the structure of modern digital substations based on the digital interface according to the IEC 61850 standard is noted.

scholarly journals Towards Efficient Milling of Multi-Cavity Aeronautical Structural Parts Considering ACO-Based Optimal Tool Feed Position and Path

Micromachines ◽  
2021 ◽  
Vol 12 (1) ◽  
pp. 88
Author(s):  
Yupeng Xin ◽  
Yuanheng Li ◽  
Wenhui Li ◽  
Gangfeng Wang
Keyword(s):  
High Speed ◽  
Tool Path ◽  
Milling Process ◽  
Ant Colony ◽  
Machining Accuracy ◽  
Ant Colony Optimization Algorithm ◽  
Peripheral Milling ◽  
Structural Part ◽  
Milling Method ◽  
Structural Parts

Cavities are typical features in aeronautical structural parts and molds. For high-speed milling of multi-cavity parts, a reasonable processing sequence planning can significantly affect the machining accuracy and efficiency. This paper proposes an improved continuous peripheral milling method for multi-cavity based on ant colony optimization algorithm (ACO). Firstly, by analyzing the mathematical model of cavity corner milling process, the geometric center of the corner is selected as the initial tool feed position. Subsequently, the tool path is globally optimized through ant colony dissemination and pheromone perception for path solution of multi-cavity milling. With the advantages of ant colony parallel search and pheromone positive feedback, the searching efficiency of the global shortest processing path is effectively improved. Finally, the milling programming of an aeronautical structural part is taken as a sample to verify the effectiveness of the proposed methodology. Compared with zigzag milling and genetic algorithm (GA)-based peripheral milling modes in the computer aided manufacturing (CAM) software, the results show that the ACO-based methodology can shorten the milling time of a sample part by more than 13%.

Collision-Free Tool Path Generation for Five-Axis High Speed Machining

2011 ◽  
Vol 474-476 ◽  
pp. 961-966 ◽  
Author(s):  
Li Qiang Zhang ◽  
Min Yue
Keyword(s):  
Image Analysis ◽  
Collision Detection ◽  
High Speed ◽  
Tool Path ◽  
Geometric Model ◽  
High Speed Machining ◽  
Analysis Method ◽  
Geometric Information ◽  
Detection Approach ◽  
Five Axis

Collision detection is a critical problem in five-axis high speed machining. Using a combination of process simulation and collision detection based on image analysis, a rapid detection approach is developed. The geometric model provides the cut geometry for the collision detection and records a dynamic geometric information for in-process workpiece. For the precise collision detection, a strategy of image analysis method is developed in order to make the approach efficient and maintian a high detection precision. An example of five-axis machining propeller is studied to demonstrate the proposed approach. It has shown that the collision detection task can be achieved with a near real-time performance.

Research on Chamfer Software of Complex Parts

2013 ◽  
Vol 631-632 ◽  
pp. 1335-1341
Author(s):  
Shi Yong ◽  
Wen Tao Liu
Keyword(s):  
3D Model ◽  
Tool Path ◽  
Machining Parameters ◽  
Cad Cam ◽  
Programming Software ◽  
A Chain ◽  
Definition Of ◽  
Complex Parts ◽  
Cam Software ◽  
Location Point

In order to meet the needs of enterprises for chamfering complex parts, based on the customization of commercial CAD/CAM software, chamfer programming software is developed. According to user’s machining demands for a part, a chain of edges of a part is extracted from its 3D model. With preprocessing of the chain of edges, the continuity of the chain is estimated, and the start and end point of those edges are automatic obtained. Furthermore, with human-machine dialogue, machining parameters is set by users. By definition of the primary and secondary surfaces of the chain of edges, and interpolation of the edges, the positions of cutter location point and postures of cutter are calculated. Finally the interference of tool path is checked, and tool path is simulated. The software solves the programming problem of chamfering complex parts.

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