Research on Five-axis NC Simulation and Parameter Optimization for Aviation Integral Impeller

2018 ◽  
Vol 12 (3) ◽  
pp. 186-192
Author(s):  
Yujun Cai ◽  
Guohe Li ◽  
Hui Lu ◽  
Meng Liu
Keyword(s):  
Parameter Optimization ◽  
Nc Simulation ◽  
Five Axis

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.

Optimal Tool Orientation for Five-Axis Tool-End Machining by Swept Envelope Approach

2004 ◽  
Author(s):  
John C. J. Chiou ◽  
Yuan-Shin Lee
Keyword(s):  
Tool Path ◽  
Tool Orientation ◽  
Error Sources ◽  
Part Geometry ◽  
Machining Errors ◽  
Nc Simulation ◽  
Part Surface ◽  
Tool Motion ◽  
Five Axis ◽  
Cutting Direction

This paper presents a swept envelope approach to determining the optimal tool orientation for five-axis tool-end machining. The swept profile of the cutter is determined based on the tool motion. By analyzing the swept profile against the part geometry, four types of machining errors (local gouge, side gouge, rear gouge, and global collision) are identified. The tool orientation is then corrected to avoid such errors. The cutter’s swept envelope is further constructed by integrating the intermediate swept profiles, and can be applied to NC simulation and verification. This paper presents the explicit solution for the swept profile of a general cutter in five-axis tool-end machining. The relation of the swept profile, the part geometry, the tool motion, and the machining errors is developed. Therefore, the error sources can be detected early and prevented during tool path planning. The analytical results indicate that the optimal tool orientation occurs when the curvature of the cutter’s swept profile matches with the curvature of the local part surface. In addition, the optimal cutting direction generally follows the minimum curvature direction. Computer illustrations and example demonstrations are shown in this paper. The results reveal the developed method can accurately determine the optimal tool orientation and efficiently avoid machining errors for five-axis tool-end machining.

Five-Axis Swept Volumes for Graphic NC Simulation and Verification

1989 ◽  
Author(s):  
K. Sambandan ◽  
K. K. Wang
Keyword(s):  
Nc Machining ◽  
Image Space ◽  
Numerical Control ◽  
Mathematical Basis ◽  
Nc Simulation ◽  
Swept Volumes ◽  
Nc Milling ◽  
Depth Buffer ◽  
Swept Volume ◽  
Five Axis

Abstract This paper explains in detail a simulator that has been developed for graphic verification of five-axis Numerical Control (NC) machining. Exact parametric representations for the surfaces generated by common NC milling cutters during five-axis motions have been derived using the theory of envelopes as the mathematical basis. Parts of these surfaces form the boundary of the total swept volume generated. For each cutting motion, the swept volume of the cutter is determined and then subtracted from the stock. The Boolean subtraction is done in the image space at the pixel level, using a modified depth-buffer algorithm. A shaded image of the “as machined” part at the end of each cutting motion is then displayed for verification.

Accurate 3D Tool Swept Volume Generation Method for 5-Axis NC Machining Simulation

2011 ◽  
Vol 204-210 ◽  
pp. 989-993 ◽  
Author(s):  
Zhi Xiang Shao ◽  
Rui Feng Guo ◽  
Jie Li ◽  
Jian Jun Peng
Keyword(s):  
Experimental Result ◽  
Moving Frame ◽  
Generation Algorithm ◽  
Motion Feature ◽  
Nc Simulation ◽  
Surface Envelope ◽  
Nc Machining Simulation ◽  
Swept Volume ◽  
Five Axis ◽  
Curve Equation

Presented in this article is a new accurate tool swept volume generation algorithm based on a generalized cutter for five-axis NC simulation and verification. Based on the surface envelope theory and the differential geometry, using analytical method, the strict deduction process of critical curve equation and swept envelope equation for generalized cutter are given. The motion feature of the cutter in five-axis machining is analyzed and the moving frame is established; Then, the detailed solving method of the cutter’s velocity is presented. Further, the accurate swept volume expression method and generation algorithm for generalized cutter are achieved. At last, the correctness and efficiency of the algorithm is verified by a fillet-end cutter’s experimental result.

Optimal Tool Orientation for Five-Axis Tool-End Machining by Swept Envelope Approach

2005 ◽  
Vol 127 (4) ◽  
pp. 810-818 ◽  
Author(s):  
John C. J. Chiou ◽  
Y. S. Lee
Keyword(s):  
Tool Path ◽  
Tool Orientation ◽  
Error Sources ◽  
Part Geometry ◽  
Machining Errors ◽  
Nc Simulation ◽  
Part Surface ◽  
Tool Motion ◽  
Five Axis ◽  
Cutting Direction

This paper presents a swept envelope approach to determining the optimal tool orientation for five-axis tool-end machining. The swept profile of the cutter is determined based on the tool motion. By analyzing the swept profile against the part geometry, four types of machining errors (local gouge, side gouge, rear gouge, and global collision) are identified. The tool orientation is then corrected to avoid such errors. The cutter’s swept envelope is further constructed by integrating the intermediate swept profiles, and can be applied to NC simulation and verification. This paper analyzes the properties of the swept profile of a general cutter in five-axis tool-end machining. The relation of the swept profile, the part geometry, the tool motion, and the machining errors is developed. Therefore, the error sources can be detected early and prevented during tool path planning. The analytical results indicate that the optimal tool orientation occurs when the curvature of the cutter’s swept profile matches with the curvature of the local part surface. In addition, the optimal cutting direction generally follows the minimum curvature direction. Computer illustrations and example demonstrations are shown in this paper. The results reveal the developed method can accurately determine the optimal tool orientation and efficiently avoid machining errors for five-axis tool-end machining.

Efficient NC Simulation for Multi-Axis Solid Machining With a Universal APT Cutter

2009 ◽  
Vol 9 (2) ◽  
Author(s):  
Hong-Tzong Yau ◽  
Lee-Sen Tsou
Keyword(s):  
Computer Aided Design ◽  
Numerical Control ◽  
Tool Geometry ◽  
Algebraic Equations ◽  
Sculptured Surfaces ◽  
Simulation Accuracy ◽  
Nc Simulation ◽  
Marching Cube Algorithm ◽  
Voxel Representation ◽  
Five Axis

In multi-axis machining of dies and molds with complex sculptured surfaces, numerical control (NC) simulation/verification is a must for the avoidance of expensive rework and material waste. Despite the fact that NC simulation has been extensively used by industries for many years, efficient, accurate, and reliable view-independent simulation of multi-axis NC machining still remains a difficult challenge. This paper presents the use of adaptive voxel data structure in conjunction with the modeling of a universal cutter for the development of an efficient and reliable multi-axis (typically five-axis) simulation procedure. The octree-based voxel representation of the workpiece saves a significant amount of memory space without sacrificing the simulation accuracy. Rendering of the voxel-based model is view independent and does not suffer from any aliasing effect, due to the real-time triangulation of the boundary surfaces using an extended marching cube algorithm. Implicit algebraic equations are used to model the automatically programed tool geometry, which can represent a universal cutter with high precision. In addition, the proposed method allows users to perform error analysis and gouging detection by comparing the machined surfaces with the original computer-aided design (CAD) model. Illustration of the implementation and experimental results demonstrate that the proposed method is reliable, accurate, and highly efficient.

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