scholarly journals Development of Direction-Parallel Strategy for Shorting A Tool Path in The Triangular Pocket Machining

2019 ◽  
Vol 18 (1) ◽  
pp. 1-7 ◽  
Author(s):  
Mochammad Chaeron ◽  
Budi Saputro Wahyuaji ◽  
Apriani Soepardi
Keyword(s):  
Path Length ◽  
Tool Path ◽  
Machining Efficiency ◽  
Machining Time ◽  
Pocket Machining ◽  
Direction Parallel ◽  
Numerical Examples ◽  
Tool Paths ◽  
Machining Strategy ◽  
Parallel Strategy

The machining strategy is one of the parameters which practically influences the time of the different manufacturing geometric forms. The machining time directly relates to the machining efficiency of the tool paths. In area milling machining, there are two main types of tool path strategies: a direction-parallel milling and contour-parallel milling. Then direction-parallel milling is simple compared with a contour-parallel strategy. This paper proposes a new model of the direction-parallel machining strategy for triangular pockets to reduce the tool path length. The authors develop an analytical model by appending additional the tool path segments to the basis tool path for cutting un-machined area or scallops, which remained along the boundary. To validate its results, the researchers have compared them to the existing model found in the literature. For illustrating the computation of this model, the study includes two numerical examples. The results show that the proposed analytic direction-parallel model can reduce the total length of machining. Thus, it can take a shorter time for milling machining.

Use of a virtual milling system to generate power-aware tool paths for 2.5-dimensional pocket machining

2019 ◽  
Vol 233 (13) ◽  
pp. 2419-2435 ◽  
Author(s):  
David Manuel Ochoa González ◽  
Joao Carlos Espindola Ferreira
Keyword(s):  
Power Consumption ◽  
Tool Path ◽  
Tool Path Generation ◽  
Path Generation ◽  
Machining Time ◽  
Power Requirement ◽  
Pocket Machining ◽  
Direction Parallel ◽  
Generation Algorithm ◽  
Tool Paths

Traditional (direction-parallel and contour-parallel) and non-traditional (trochoidal) tool paths are generated by specialized geometric algorithms based on the pocket shape and various parameters. However, the tool paths generated with those methods do not usually consider the required machining power. In this work, a method for generating power-aware tool paths is presented, which uses the power consumption estimation for the calculation of the tool path. A virtual milling system was developed to integrate with the tool path generation algorithm in order to obtain tool paths with precise power requirement control. The virtual milling system and the tests used to calibrate it are described within this article, as well as the proposed tool path generation algorithm. Results from machining a test pocket are presented, including the real and the estimated power requirements. Those results were compared with a contour-parallel tool path strategy, which has a shorter machining time but has higher in-process power consumption.

Aggressive Spiral Toolpaths for Pocket Machining Based on Medial Axis Transformation

2017 ◽  
Vol 139 (5) ◽  
Author(s):  
Nuodi Huang ◽  
Roby Lynn ◽  
Thomas Kurfess
Keyword(s):  
High Speed ◽  
Medial Axis ◽  
Removal Rate ◽  
Salient Feature ◽  
Machining Time ◽  
Additional Material ◽  
Pocket Machining ◽  
Direction Parallel ◽  
Medial Axis Transformation ◽  
Machining Strategy

High-speed machine tools typically provide high spindle speeds and feedrates to achieve an effective material removal rate (MRR). However, it is not possible to realize the full extent of their high-speed capabilities due to the sharp corners of toolpaths which are introduced by conventional machining strategies, such as contour- and direction-parallel toolpaths. To address this limitation, spiral toolpaths that can reduce the magnitude of sudden direction changes have been developed in previous researches. Nevertheless, for some pockets, the average radial cutting width is significantly decreased while the total length of the toolpath is significantly increased as compared to contour- and direction-parallel toolpath. In this situation, spiral toolpath may take more machining time. To overcome these drawbacks, an aggressive spiral toolpath generation method based on the medial axis (MA) transformation is proposed in machining pocket without islands inside, which refers to no additional material inside the counter. The salient feature of this work is that it integrates the advantages of both conventional contour-parallel machining strategy and the existing spiral toolpath machining strategy. The cutting width at each MA point is determined based on the diameter of the locally inscribed circle (LIC) of the MA point and the topological structure of MA. A distance-constrained contour determination algorithm is utilized to calculate the toolpath for each pass. Finally, a circular arc transition strategy is used to transform all the isolated passes into a spiral toolpath. Experiments are conducted to show the effectiveness of the proposed method.

Time-Efficient Trochoidal Tool Path Generation for Milling Arbitrary Curved Slots

2019 ◽  
Vol 141 (3) ◽  
Author(s):  
Ke Xu ◽  
Baohai Wu ◽  
Zhaoyu Li ◽  
Kai Tang
Keyword(s):  
High Speed ◽  
Tool Path ◽  
Removal Rate ◽  
Machining Efficiency ◽  
Machining Time ◽  
Tool Paths ◽  
Engagement Angle ◽  
New Type ◽  
The Given ◽  
Slot Cutting

Trochoidal (TR) tool paths have been a popular means in high-speed machining for slot cutting, owing to its unique way of cyclically advancing the tool to avoid the situation of a full tool engagement angle suffered by the conventional type of slot cutting. However, advantageous in lowering the tool engagement angle, they sacrifice in machining efficiency—to limit the tool engagement angle, the step distance has to be carefully controlled, thus resulting in a much longer total machining time. Toward the objective of improving the machining efficiency, in this paper, we propose a new type of TR tool path for milling an arbitrary curved slot. For our new type of TR tool path, within each TR cycle, rather than moving circularly, the tool moves in a particular way such that the material removal rate is maximized while the given maximum engagement angle is fully respected. While this type of TR tool path works perfectly only for circular slots (including straight ones), by means of an adaptive decomposition and then a novel iso-arc-length mapping scheme, it is successfully applied to any general arbitrarily curved slot. Our experiments have confirmed that, when compared with the conventional TR tool paths, the proposed new type of TR tool path is able to significantly reduce the total machining time by as much as 25%, without sacrificing the tool wear.

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.

Efficient NC Tool Path Planning Based on the Subdivision of Sculptured Surface

2014 ◽  
Vol 635-637 ◽  
pp. 497-501
Author(s):  
Li Min ◽  
Biao Bai ◽  
Yu Hou Wu ◽  
De Hong Zhao
Keyword(s):  
Path Planning ◽  
Tool Path ◽  
High Efficiency ◽  
Parametric Method ◽  
Sculptured Surface ◽  
Machining Efficiency ◽  
Tool Path Planning ◽  
Tool Paths ◽  
Surface Subdivision ◽  
Planning Methods

In this paper, we have presented a method to generate efficient NC tool paths based on the surface subdivision. The main objective is to achieve high efficiency in the machining of sculptured surface. The NC machining efficiency can be improved by segmenting the whole surface into distinct areas according to the characters of sculptured surface and by using different size mills and different tool path planning methods to machine the areas. The iso-parametric method and large mills are used in the curvature changing little areas. While the iso-scallop method and small mills are used in curvatures changing large areas. This can make full use of tool path generation methods and mills, which improve the machining efficiency of sculpture effectively.

Benefit Evaluation for Manufacturing of Marine Propellers

2008 ◽  
Author(s):  
Der-Min Tsay ◽  
Hsin-Pao Chen ◽  
Sa´ndor Vajna ◽  
Michael Schabacker
Keyword(s):  
Cost Model ◽  
Cost Savings ◽  
Machining Efficiency ◽  
Machining Time ◽  
Marine Propellers ◽  
Tool Paths ◽  
Benefit Evaluation ◽  
Cad Cam ◽  
Increase Productivity ◽  
The Cost

To increase productivity of marine propellers by raising machining efficiency, this paper presents the zigzag/spiral tool paths generation algorithm based on the arc base curve approach for three-axis machining of curved surfaces of propellers. By considering the shapes of selected cutters with different types of tool paths generated by the proposed procedure, machining efficiency can be calculated and simulated. To verify the accuracy and effectiveness of the developed approach, numerical and experimental results of machining of propeller surfaces are compared. It was proved that the machining time can be cut down up to 19% by using zigzag tool paths with a toroidal cutter. In addition, the machining knowledge revealed here can be accumulated for benefit evaluation in the manufacturing process with existing CAD/CAM systems. From the cost model, design, and process views, the overall cost savings after 5 years are investigated, and the expected benefit yield is about 45%.

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.

Efficient Method for Tool Path Generation Based on Region Intersection for Complex Mesh Surface Machining

2013 ◽  
Vol 774-776 ◽  
pp. 1438-1441
Author(s):  
Xiao Bing Chen ◽  
Kun Yu
Keyword(s):  
Efficient Method ◽  
Tool Path ◽  
Tool Path Generation ◽  
Machining Efficiency ◽  
Path Generation ◽  
Surface Machining ◽  
Tool Paths ◽  
Mesh Surface ◽  
Fitting Method ◽  
Local Fitting

The machining efficiency of conventional section plane method is low for complex mesh surface machining. An efficient method for tool path generation based on region intersection is proposed. The mesh surface is first divided into a series of intersection regions, then vertex curvatures in perpendicular directions of tool paths are estimated by local fitting method, and variable tool path intervals are computed according to the curvatures, scallop height and cutter radius, finally redundant cutter location points are removed according to machining precision. Experiment results indicate that tool paths generated by proposed method are avail to promote machining efficiency of complex mesh surface machining.

scholarly journals Optimization of Tool Path Length on Three-Dimensional Drilling Application Using Ant Colony Algorithm

2021 ◽  
Vol 2129 (1) ◽  
pp. 012060
Author(s):  
Muhammad Danial Ikmal bin Rusman ◽  
Haslina Abdullah ◽  
Mohamad Shukri Zakaria ◽  
Norfazillah Talib ◽  
Lee Woon Kiow ◽  
...  
Keyword(s):  
Path Length ◽  
Ant Colony Algorithm ◽  
Tool Path ◽  
Block Design ◽  
Ant Colony ◽  
Drilling Process ◽  
Machining Time ◽  
Evaporation Coefficient ◽  
Simple Block ◽  
Complex Block

Abstract The lower machining time is important characteristic in the drilling machining process. Drilling process costs will increase if the machining time is high. Therefore, the main objective of this research is to develop Ant Colony Algorithm (ACO) to reduce the machining time by obtain the optimal tool path length. By using this algorithm, it can minimize the tool path length and significantly decreasing the machining time of drilling process. Simulating in 3-dimensional drilling on ACO has been constructed to minimize the shortest path of the drilling process. There are two type of workpiece has been used, which is simple block with 10 holes and complex block design that has 154 holes. ACO algorithm has been developed in Matlab R2017b to determine the optimal parameters of ACO of tool path length in drilling. Besides, simulation also has been done to investigate the effect of ACO parameter which is weight of pheromone (α), weight of trail (β), evaporation coefficient (e), and number of iterations. As a result, by define the parameter of iteration number at 900, the optimum parameter of weight of pheromone (α) is 5, weight of trail (β) is 4 and evaporation coefficient (e) is 0.4. Based on these parameters, the minimal tool path length obtain for simple and complex model are 286.965 mm and 6770.9860 mm respectively. Then, the result of tool path length of ACO simulation has been compared with the Mastercam outcome. ACO achieves a total tool path length of 286.965 mm while Mastercam achieved 569.878 mm for simple block design. Meanwhile, for complex block design, ACO produces a total tool path length of 6770.9860 mm while Mastercam has generate 55828.9050 mm of tool path length. By comparing these two approaches, ACO and Mastercam, ACO has that the short total tool path length by 49.64% on simple block design and 87.87% for complex block design.

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