Solid Modeling and Machining Approach of the Impeller Based on Five-Axis Machine Tool

2011 ◽  
Vol 189-193 ◽  
pp. 801-804 ◽  
Author(s):  
Yu Xia Zhao ◽  
Jie Jian Di ◽  
De Wen Gao
Keyword(s):  
Cutting Tool ◽  
Cnc Machining ◽  
Centrifugal Impeller ◽  
Software Simulation ◽  
Location Data ◽  
Geometry Model ◽  
The Core ◽  
Engine Components ◽  
Five Axis ◽  
Cutter Location Data

An impeller is the core of aviation engine components, the processing quality has a decisive impact on the performance of the engine. An impeller is also one of the most important basic components of centrifugal compressor. When a three-axis CNC machining centre is used for producing an impeller, great difficulties, i.e. collisions between the cutting tool and the impeller, can occur. As the surface is normally twisted in design to achieve the required performance, it can cause overcut and collision problems during machining. To solve these problems, an integrated five-axis machining approach for a centrifugal impeller by combining related machining technologies is developed. As a result, Cutter Location data based on the geometry model of blade and hub of the impeller are generated. Finally, the Cutter Location data is verified through software simulation. The results prove that the machining methodology adopted is useful and efficient.

Tool Path Planning and Machining Experiment for a Centrifugal Impeller Based on Five-Axis Machine Tool

2011 ◽  
Vol 211-212 ◽  
pp. 629-633
Author(s):  
Yu Xia Zhao ◽  
Jie Jian Di ◽  
De Wen Gao
Keyword(s):  
Tool Path ◽  
Geometric Model ◽  
Three Dimensional ◽  
Centrifugal Impeller ◽  
Geometric Complexity ◽  
The Core ◽  
Engineering Data ◽  
Nc Program ◽  
Engine Components ◽  
Five Axis

An impeller is the core of aviation engine components, the processing quality have a decisive impact on the performance of the engine. An impeller is one of most important basic components of centrifugal compressor. However, it is very difficult to machine and model because of the twisted blades. For such geometric complexity, it is the general practice to adopt five-axis machining. Based on the actual engineering data, pro/Engineer software is applied to produce three-dimensional geometric model of the integrated impeller, some general principles followed by machining and modeling the impeller are brought forward. Furthermore, analysis and research were made for tool path of the integrated impeller machining. NC program is exported successfully to DEMAGE five-axis machine from PowerMill software where machining verification as a centrifugal impeller example was carried on. The results of verification show that the machining methodology and procedure adopted are successful.

Geometric deviation reduction method for interpolated toolpath in five-axis flank milling of the S-shaped test piece

2019 ◽  
Vol 234 (5) ◽  
pp. 910-919 ◽  
Author(s):  
Liping Wang ◽  
Weitao Li ◽  
Hao Si ◽  
Xing Yuan ◽  
Yuzhe Liu
Keyword(s):  
Test Piece ◽  
Reduction Method ◽  
Linear Interpolation ◽  
Machining Process ◽  
Flank Milling ◽  
Machined Surface ◽  
Location Data ◽  
Geometric Deviation ◽  
Five Axis ◽  
Cutter Location Data

Geometric deviation, defined as the distance between the designed surface and the machined surface, is an important component of machining errors in five-axis flank milling of the S-shaped test piece. Since the interpolated toolpath in practical machining process is the approximation of the theoretical toolpath, the geometric deviation caused by the interpolated toolpath appears. To overcome this problem, a novel geometric deviation reduction method is suggested in this study. First, the features of the S-shaped test piece are analyzed. Second, the theoretical toolpath is generated according to the designed surface and the cutter location data is obtained by discretizing the theoretical toolpath. The linear interpolation of the cutter location data is carried out to obtain the interpolated toolpath. Then, the geometric deviation is modeled by calculating the Hausdorff distance between the tool axis trajectory surface based on the interpolated toolpath and the offset surface of the designed surface. Finally, the geometric deviation is reduced by optimizing the cutter location data without inserting more cutter location points. The machining experiment is conducted to verify the effectiveness of the proposed method. The experimental results agree with the simulation results, and both of them indicate the geometric deviation on the machined surface reduces after optimization.

A New Compensation Method for Multi-Choice of a Five-Axis Machine with a Tilting Head

2013 ◽  
Vol 364 ◽  
pp. 386-390
Author(s):  
Chun Hui Yin ◽  
Huai Jing Jing ◽  
Nuo Di Huang ◽  
Fei Ren
Keyword(s):  
Coordinate Transformation ◽  
Choice Function ◽  
Control Data ◽  
Mechanism Model ◽  
Location Data ◽  
Nc Programming ◽  
Cutting Experiment ◽  
Machine Control ◽  
Five Axis ◽  
Cutter Location Data

Postprocess capable of converting the cutter location data to machine control data is an important interface between the NC programming design and manufacture.Due to the fact that current research on multi-axis postprocess methods mostly deals with machine tool configurations whose linear and rotational movements are orthogonal, an efficient postprocess algorithm for the five-axis machine with a tilting head is presented in this paper.DMU 80P which is a five-axis machine with a tilting head is selected as an example.Its mechanism model is proposed in this paper according to the mechanism theory.The kinematics model is established using coordinate transformation,and the solution of this model is discussed.Based on these,a window-based post-processor with multi-choice function was developed by VS2010 language.Through the verification by the commercial solid cutting software VERICUT,the feasibility of the algorithm proposed is demonstrated.At last,a real impeller cutting experiment has been conducted and the result further verifies the correctness of the algorithm.

Generation of Five-Axis Cutter Paths for a Ball-End Cutter With Global Interference Checking

1998 ◽  
Author(s):  
Der Min Tsay ◽  
Wei Feng Yan
Keyword(s):  
End Mill ◽  
Ball End Mill ◽  
Location Data ◽  
Tool Paths ◽  
Contact Points ◽  
Surface Data ◽  
Five Axis ◽  
Interference Checking ◽  
Cutter Location Data ◽  
Projected Distance

A simple, yet useful procedure is developed to generate tool paths with global interference checking for five-axis machining of turbomachinery components with complex geometries. Based on the projected distance between the surface data and the cutter-axis of a cylindrical ball-end mill, interference between the surface of a workpiece and the cutter can be detected. Given the cutter contact points of the surface and the cutter’s size, it can produce the cutter location data without incurring interference through relatively rotating and tilting the workpiece. Applications of the developed approach to five-axis machining of centrifugal compressor impellers with thirteen and fifteen blades are illustrated to demonstrate the usefulness and reliability of the procedure.

A Five-Axis CNC Machine Postprocessor Based on Inverse Kinematics Transformation

2012 ◽  
Vol 622-623 ◽  
pp. 525-530
Author(s):  
Tran Duc Tang
Keyword(s):  
Inverse Kinematics ◽  
Visual Basic ◽  
Cnc Machine ◽  
Location Data ◽  
Nc Program ◽  
Basic Language ◽  
Nc Data ◽  
Visual Basic Language ◽  
Five Axis ◽  
Cutter Location Data

This paper presents a postprocessor for five-axis milling machine that capable of converting CL (cutter location) data to machine control data (NC program). The proposed postprocessor method is based on inverse kinematics transformation and postprocessor module is programmed in Visual Basic language. The Deckel Maho DMU 50 eVoluion five-axis machine with two rotary axes (B and C) on the table is modeled and verified in software VERICUT® to validate the NC data generated by proposed postprocessor.

Design of a Cutting Point Control Algorithm for Five-Axis Machining

2012 ◽  
Vol 249-250 ◽  
pp. 702-706
Author(s):  
Chen Hua She ◽  
Tsung Hua Yang
Keyword(s):  
Control Algorithm ◽  
Cutting Tools ◽  
Simulation Software ◽  
Precision Manufacturing ◽  
Nc Code ◽  
Location Data ◽  
Point Control ◽  
Five Axis ◽  
Cutting Point ◽  
Cutter Location Data

Five-axis machine tool with two additional rotary axes has been widely used in defense, aerospace and the consumer industries, and is an important process of precision manufacturing. Traditional five-axis program depends on the machine tool’s configuration and machining setting. This leads to inconvenience of reprogramming five-axis NC code for the end users. This paper proposes a cutting point control algorithm for five-axis machining. Although the commercial advanced controllers provide this function, they are very expensive and restricted to export. The developed algorithm can be embedded to the PC-based controller so that the specific cutter location data can be transformed and employed easily for different cutting tools. Verification using VERICUT solid cutting simulation software demonstrated the correctness of the generated cutter location data.

Ruled Layer Generation Between Two Freeform Curves by Normal and Distance Matching

2006 ◽  
Author(s):  
Kuntal Samanta ◽  
Bahattin Koc
Keyword(s):  
Piecewise Linear ◽  
Optimization Method ◽  
Layered Manufacturing ◽  
Cnc Machining ◽  
Curve Matching ◽  
Location Data ◽  
Spline Curves ◽  
Point To Point ◽  
Number Of Segments ◽  
Cutter Location Data

A new curve matching method is proposed to generate non-self-intersecting and non-twisted ruled layers for application in diverse fields such as layered manufacturing, offsetting and multi-axis CNC machining. The method establishes point-to-point correspondence represented by a set of ruling lines between two directrices of the ruled surface. The directrices are given as non-self-intersecting, closed, at least C1 continuous, planar, B-spline curves. To match the points on the directrices, a heuristic optimization method developed with the objective is to maximize the sum of the inner products of the unit normals at the end points of the ruling lines and minimize the sum of the lengths of connecting ruling lines. The generated ruling lines can be used as cutter location data for multi-axis NC machining of ruled surfaces. Moreover, by subdividing the ruling lines into equal number of segments, one can construct a series of intermediate piecewise linear curves that represent the metamorphosis between the directrices. Implementation and examples are also presented.

Generation of Five-Axis Cutter Paths for Turbomachinery Components

1999 ◽  
Vol 123 (1) ◽  
pp. 50-56 ◽  
Author(s):  
D. M. Tsay ◽  
W. F. Yan ◽  
H. C. Ho
Keyword(s):  
End Mill ◽  
Ball End Mill ◽  
Location Data ◽  
Tool Paths ◽  
Contact Points ◽  
Surface Data ◽  
Five Axis ◽  
Interference Checking ◽  
Cutter Location Data ◽  
Projected Distance

A simple, yet useful algorithm is developed to generate tool paths with global interference checking for five-axis point milling of turbomachinery components. Based on the projected distance between the surface data and the cutter-axis of a cylindrical ball-end mill, interference between the surface of a workpiece and the cutter can be detected. Given the cutter contact points of the surface and the cutter’s size, it can produce the cutter location data without incurring interference through relatively rotating and tilting the workpiece. Applications of the developed procedure to five-axis machining of centrifugal compressor impellers with 13 and 15 blades are illustrated to demonstrate the usefulness and reliability of the approach.

scholarly journals Precision Sculptured Surface CNC Machining Using Cutter Location Data

2016 ◽  
Vol 686 ◽  
pp. 224-233
Author(s):  
Nikolaos A. Fountas ◽  
Nikolaos M. Vaxevanidis ◽  
Constantinos I. Stergiou ◽  
Redha Benhadj-Djilali
Keyword(s):  
Tool Path ◽  
Low Cost ◽  
Cnc Machining ◽  
Sculptured Surface ◽  
Sculptured Surfaces ◽  
Rough Machining ◽  
Machining Error ◽  
Location Data ◽  
Tool Paths ◽  
Cutter Location Data

Industrial parts with sculptured surfaces are typically, manufactured with the use of CNC machining technology and CAM software to generate surface tool paths. To assess tool paths computed for 3-and 5-axis machining, the machining error is evaluated in advance referring to the parameter controlling the linearization of high-order curves, as well as the scallop yielded as a function of radial cutting engagement parameter. The two parameters responsible for the machining error are modeled and corresponding cutter location data for tool paths are utilized to compare actual trajectories with theoretical curves on a sculptured surface assessing thus the deviation when virtual tools are employed to maintain low cost; whilst ensuring high precision cutting. This operation is supported by applying a flexible automation code capable of computing the tool path; extracting its CL data; importing them to the CAD part and finally projecting them onto the part’s surface. For a given tolerance, heights from projected instances are computed for tool paths created by changing the parameters under a cutting strategy, towards the identification of the optimum tool path. To represent a global solution rough machining is also discussed prior to finish machining where the new proposals are mainly applied.

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