Virtual Five-Axis Milling of Free-Form Surface-Part II: Feed Optimization

2010 ◽  
Vol 29-32 ◽  
pp. 430-435
Author(s):  
Li Qiang Zhang ◽  
Ye Cui Yan
Keyword(s):  
Process Optimization ◽  
Sequential Quadratic Programming ◽  
Tool Path ◽  
Milling Process ◽  
Free Form ◽  
Machining Time ◽  
Mechanics Model ◽  
Finished Surface ◽  
Free Form Surface ◽  
Five Axis

This paper presents process optimization for the five-axis milling based on the mechanics model explained in Part I. The process is optimized by varying the feed as the tool-workpiece engagements. The linear and angular feedrates are optimized by sequential quadratic programming. Sharp feedrate changes may result in undesired feed-marks on the finished surface. The adopted step is to update the the original CL file with optimized and filtered feedrate commands. The five-axis milling process is simulated in a virtual enviroment, and the resulting feedrate outputs are stored at each position along the tool path. The new feedrate profiles are shown to considerably reduce the machining time while avoiding process faults.

Feed Optimization for Five-Axis Flank Milling Thin-Walled Parts

2014 ◽  
Vol 703 ◽  
pp. 150-155
Author(s):  
Ming Yong Wang
Keyword(s):  
Process Optimization ◽  
Sequential Quadratic Programming ◽  
Tool Path ◽  
Milling Process ◽  
Flank Milling ◽  
Machining Time ◽  
Mechanics Model ◽  
Finished Surface ◽  
Thin Walled ◽  
Five Axis

This paper presents process optimization for the five-axis milling based on the mechanics model explained in Part I. The process is optimized by varying the feed as the tool-workpiece engagements. The linear and angular feedrates are optimized by sequential quadratic programming. Sharp feedrate changes may result in undesired feed-marks on the finished surface. The adopted step is to update the the original CL file with optimized and filtered feedrate commands. The five-axis milling process is simulated in a virtual enviroment, and the resulting feedrate outputs are stored at each position along the tool path. The new feedrate profiles are shown to considerably reduce the machining time while avoiding process faults.

Tool Path Generation for Five-Axis Controlled Machining of Free-Form Surface Using Barrel Tool: Control of Contact Point on Cutting Edge

2020 ◽  
Author(s):  
Tomonobu Suzuki ◽  
Koichi Morishige
Keyword(s):  
Tool Path ◽  
Contact Point ◽  
Cutting Edge ◽  
Free Form ◽  
End Mill ◽  
Ball End Mill ◽  
Surface Machining ◽  
Free Form Surface ◽  
The Cost ◽  
Five Axis

Abstract This study aimed to improve the efficiency of free-form surface machining by using a five-axis controlled machine tool and a barrel tool. The barrel tool has cutting edges, with curvature smaller than the radius, increasing the pick feed width compared with a conventional ball end mill of the same tool radius. As a result, the machining efficiency can be improved; however, the cost of the barrel tool is high and difficult to reground. In this study, a method to obtain the cutting points that make the cusp height below the target value is proposed. Moreover, a method to improve the tool life by continuously and uniformly changing the contact point on the cutting edge is proposed. The usefulness of the developed method is confirmed through machining simulations.

Studies on the Algorithm for Five-Axis NC Machining with Triangular Facet Model

2013 ◽  
Vol 385-386 ◽  
pp. 726-730
Author(s):  
Ren Xian Geng ◽  
Hou Jun Qi ◽  
Xin Pan ◽  
Zhi Gang Liu
Keyword(s):  
Tool Path ◽  
Nc Machining ◽  
Surface Shape ◽  
Free Form ◽  
Cutting Efficiency ◽  
Triangular Facet ◽  
Constant Scallop Height ◽  
Free Form Surface ◽  
Five Axis ◽  
Facet Model

Using five-axis equipment for NC machining of free-form surface is an effective way to improve machining quality and machining efficiency, the surface shape and the five coordinate of the complexity of the machine tool movement led to its tool path planning technology is difficult. The paper aimed at the five coordinate NC machining of free-form surface and puts forward a five-axis NC machining method based on triangular facet model. The research based on triangular facet model, using constant scallop height method to calculate the step distance and improve the cutting efficiency to a great extent. In the process, tool path is generated, combining with the method of configuration space interference free.

Machining of Free-Form Surface Base on Cutter Shaft Tilt Method with Ball-End Cutter

2011 ◽  
Vol 215 ◽  
pp. 176-181
Author(s):  
Li Min ◽  
Ke Hua Zhang
Keyword(s):  
Tool Path ◽  
Tool Path Generation ◽  
Free Form ◽  
Real Surface ◽  
End Mill ◽  
Ball End Mill ◽  
Surface Machining ◽  
Processing Accuracy ◽  
Free Form Surface ◽  
Five Axis

A new tool path generation method based on cutter shaft tilt method was proposed for free-form surface machining by using Ball-end Cutter. Firstly, it introduces the processing quality problems caused by traditional ball-end mill processing. Then cutter shaft tilt was proposed to avoid the above questions. Analyzing the different machining efficiency at the different angle, and then cutter shaft tilt compensation method which based on above method could avoid that problem was proposed. After the paths calculation to a real surface and simulation, the result shows that, comparing to traditional machining method, the new method reduced efficiently phenomenon of extruding and scratching surface. It meets five-axis processing accuracy requirements.

Free-Form Surface Five-Axis Machining Tool Path and Tool Posture Simultaneous Multi-Objective Optimization Theory Research

2011 ◽  
Vol 467-469 ◽  
pp. 900-905
Author(s):  
Shu Kun Cao ◽  
Li Song ◽  
Kai Feng Song ◽  
Jie Lv ◽  
Xiu Sheng Chen
Keyword(s):  
Tool Path ◽  
Contact Point ◽  
Free Form ◽  
Multi Objective Optimization ◽  
Scallop Height ◽  
Multi Objective ◽  
Tool Axis ◽  
Tool Posture ◽  
Free Form Surface ◽  
Five Axis

In view of all sorts of questions existing in CNC machining, such as machining vibration, so proposed a new simultaneous multi-objective optimization algorithm on free-form surface five-axis machining tool path and tool posture based on constant scallop height. In the algorithm, we first complete the surface fitting on the base of feature points obtained. Secondly calculate principal curvatures of the surface, select tools, and at the same time generate tool axis vector in the current cutter-contact point tool axis. Once again get the maximum spacing and surface curvature in accordance with the tool effective cutting radius, discrete into cutter-contact point, and calculate the cutting depth to adjust the machine feed rate. And finally connect adjacent curve path using the diagonal to achieve a continuous cutting scallop height tool path. This algorithm can achieve the goals such as the same precision, improving processing efficiency, reducing the number of tool cutting in and out, reducing cutting vibration and tool wear and so on. That is the algorithm can achieve simultaneous multi-objective optimization of the free-form surface NC machining finally.

Software Module Development for Free-Form Surface Five-Axis Machining Path and Tool Posture Simultaneous Optimization

2011 ◽  
Vol 55-57 ◽  
pp. 1932-1937
Author(s):  
Li Song ◽  
Shu Kun Cao ◽  
Kai Feng Song ◽  
Chang Zhong Wu ◽  
Wei Wei Song
Keyword(s):  
Tool Path ◽  
Three Dimensional ◽  
Path Optimization ◽  
Simultaneous Optimization ◽  
Free Form ◽  
Software Module ◽  
Tool Posture ◽  
Free Form Surface ◽  
Five Axis ◽  
Free Form Surfaces

The paper presented the development of free-form surface axis NC machining tool path optimization module. In the UG environment, have three-dimensional solid modeling to the surface, and then have the secondary development of free-form surfaces five-axis machining path optimization module through the UG/Open API and VC++6.0. This can realize NC processing path automatically generation and optimization after the three-dimensional modeling. Introduction

Kinematics-based five-axis trochoidal milling process planning for deep and curved 3D slots

2021 ◽  
pp. 1-30
Author(s):  
Zhaoyu Li ◽  
Dong He ◽  
Ke Xu ◽  
Fubao Xie ◽  
Kai Tang
Keyword(s):  
Machine Tool ◽  
Tool Path ◽  
Electric Energy ◽  
Milling Process ◽  
Heat Accumulation ◽  
Machining Time ◽  
Rotary Axes ◽  
Planning Algorithm ◽  
The One ◽  
Five Axis

Abstract Trochoidal (TR) milling is a popular means for slotting operation. Attributing to its unique circular shaped path pattern, TR milling avoids the full tool-workpiece engagement, which helps reduce the cutting heat accumulation and hence slow down the tool wear. While traditionally TR milling is only used for machining 2.5D cavities, it has now been extended to machining genuine 3D curved cavities under the realm of five-axis machining. However, since for a typical five-axis machine tool the rotary axes have a much larger moment of inertial than the three linear axes, to reduce both the total machining time and the consumed electric energy (for driving the machine tool), it is desirable to minimize the use of the two rotary axes (particularly the one with the worst moment of inertial) when planning a TR tool path for a given 3D cavity. Unfortunately, due to the newness of five-axis TR machining, there has no published reports on this subject. In this paper, we present a five-axis TR tool path planning algorithm for machining an arbitrary 3D curved cavity, which will consider the kinematical characteristics of the five-axis machine tool and try to minimize the use of the kinematically worst rotary axes, while tending to all the required constraints such as the threshold on the cutting force. Both computer simulation and physical cutting experiments of the proposed method have been conducted, and the results give a preliminary confirmation on the feasibility and advantages of the proposed method.

Machining of Free-Form Surface Method and Implementation Research with Ball-End Cutter

2011 ◽  
Vol 697-698 ◽  
pp. 244-248
Author(s):  
Ke Hua Zhang ◽  
Li Min ◽  
Dong Hui Wen
Keyword(s):  
Tool Path ◽  
Computer Hardware ◽  
Free Form ◽  
Machining Accuracy ◽  
End Mill ◽  
Ball End Mill ◽  
Surface Machining ◽  
Free Form Surface ◽  
Tool Position ◽  
Five Axis

A new tool path generation method based on Z-buffer method is proposed for free-form surface machining by using ball-end cutters. Firstly, to avoid ball-end mill cutting the workpiece, we make the cutter shaft which is perpendicular to machining surface tilt angle θ, then determine the examining area and then judge there is or not a interference occurring between ball-end mill and examining area, if there is, then make a adjustment for cutter shaft. The discretized points within the examining area are efficiently read in and stored directly by the computer hardware; no extra searching and iterative methods are needed. Simulation results show that, comparing with the traditional algorithm, the tool-position calculation time is shorter, and the phenomenon of workpiece squeezed and scratched is less in this algorithm. It meets the basic needs of five axis machining accuracy. Finally we make a practical machining experiment for cutter location generated.

Free-Form Surface Five-Axis Machining G-Code Automatic Generation System Based on Path Messages for the Different CNC System

2011 ◽  
Vol 55-57 ◽  
pp. 1441-1446
Author(s):  
Shu Kun Cao ◽  
Jia Jia ◽  
Wei Wei Song ◽  
Kai Feng Song ◽  
Jie Lv
Keyword(s):  
Control System ◽  
Tool Path ◽  
Automatic Generation ◽  
Numerical Control ◽  
Free Form ◽  
Processing Route ◽  
Numerical Control System ◽  
G Code ◽  
Free Form Surface ◽  
Five Axis

For the free-form surface 5-axis computer numerical control processing field, we can obtain the processing route information according to the secondary development of UG , it also based on the free surface 5-axis numerical control machining tool path and synchronization of posture multi-objective optimization algorithms, then develops a software module according to the analysis comparison of features and programming instructions of the Fanuc and Siemens numerical control system, This module can be realized according to the information from the path for the two numerical control system, this module generates the proper or absolute matching G-code, it also can generate the automatic G-code for many different numerical control system .

Research on Path Optimization Technology for Free-Form Surface Five-Axis NC Machining

2012 ◽  
Vol 443-444 ◽  
pp. 202-208 ◽  
Author(s):  
Shu Kun Cao ◽  
Li Song ◽  
Ke Dong ◽  
Kai Feng Song ◽  
Zhi Ming Sui
Keyword(s):  
Tool Path ◽  
Simple Calculation ◽  
Nc Machining ◽  
Cnc Machining ◽  
Path Optimization ◽  
Free Form ◽  
Surface Boundary ◽  
Scallop Height ◽  
Free Form Surface ◽  
Five Axis

In view of all sorts of questions existing in CNC machining, such as machining vibration, so proposed a new method of free-form surface NC machining path optimization based on constant scallop height. This method first discrete surface boundary into the knife touch point based on the maximum tolerance, then in accordance with the maximum allowable scallop height generates circular trajectory with the same scallop, and finally connects adjacent curve path using the diagonal to achieve a continuous cutting scallop height tool path. This method can reduce the number of tools cut in and out parts, reduce the processing vibration and tool wear, and the surface processed has the same precision. This method has simple calculation, suitable for free-form surface of CNC highspeed and precision machining.

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