Design of a CAM System for End Mills Based on Solid Modeling

2011 ◽  
Vol 201-203 ◽  
pp. 841-845
Author(s):  
Zhan Hua You ◽  
Fei Tang ◽  
Shu Zhe Li ◽  
Xiao Feng Yue ◽  
Xiao Hao Wang
Keyword(s):  
Solid Modeling ◽  
Numerical Control ◽  
Design Parameters ◽  
End Mill ◽  
Nc Code ◽  
Inner Radius ◽  
End Mills ◽  
Grinding Machine ◽  
Five Axis ◽  
Mill Machining

To facilitate the manufacturing of an end mill, this paper presents a manufacturing model of a flat-end mill using a five-axis computer numerical control (CNC) grinding machine. Using input data of end mill geometry, wheels geometry, wheel setting and machine setting, the NC code for machining will be generated directly from a solid modeling then used as input to simulate the end mill machining in 3 Dimension before machining. The 3D simulation system of the end mill grinding is generated by VBA and AutoCAD2008. Machining simulation consists of a sequence of Boolean operations on difference between the tool and the grinding wheels through NC code. Then the major design parameters of a cutter, such as relief angle and inner radius, can be verified by interrogating the section profile of its solid model. The manufacturing model presented in this paper provides a practical and efficient method for developing CAM software for the manufacture of an end mill.

A Novel CNC Grinding Method about Relief Surface of Corner Radius End Mill Based on a CAM System

2011 ◽  
Vol 120 ◽  
pp. 26-31 ◽  
Author(s):  
Cai Xia Zhao ◽  
Fei Tang ◽  
Shu Zhe Li ◽  
Xiao Hao Wang
Keyword(s):  
Numerical Control ◽  
End Mill ◽  
Nc Code ◽  
Corner Radius ◽  
Relief Surface ◽  
Cnc Grinding ◽  
Cup Wheel ◽  
Grinding Machine ◽  
Cnc Grinding Machine ◽  
Five Axis

Corner radius end mill, whose cutting capability is mostly affected by the relief surface, is a kind of highly effective end mill [1]. So a novel mathematical model of relief surface curve about corner radius end mill, which is verified with a five-axis computer numerical control (CNC) grinding machine and simulated based on a system CAM, is derived and presented in the paper. According to the proposed tool coordinates system and the mechanical coordinate of the machine, the relative motion between the cup wheel and the tool is determined. In order to obtain an accurate relief curve when machining, the model of a cup wheel edge is also introduced. The coordinates of grinding point when grinding relief surface are calculated. With the input data of the corner radius end geometry, wheels geometry, wheel setting and machine setting, the NC code is generated automatically from the program. Then the code is used to simulate in 3 Dimension before actual machining. Finally, the NC code will be used for machining in the CNC grinding machine. The roundness of the round corner in the final product is very well, means this model is effective.

A Novel CNC Grinding Method for Relief Surface Based on a CAM System

2011 ◽  
Vol 295-297 ◽  
pp. 2521-2525 ◽  
Author(s):  
Xiao Feng Yue ◽  
Fei Tang ◽  
Shu Zhe Li ◽  
Zhan Hua You ◽  
Xiao Hao Wang
Keyword(s):  
Coordinate System ◽  
Numerical Control ◽  
Grinding Wheel ◽  
End Mill ◽  
Ball End Mill ◽  
Relief Surface ◽  
Cnc Grinding ◽  
Relief Angle ◽  
Five Axis ◽  
Mill Machining

A novel algorithm for the ball-end mill relief using a five-axis computer numerical control (CNC) grinding machine and the simulation of the ball-end mill based on a CAM system is presented in this paper. In this study, In order to obtain an accurate normal relief angle, which is one of the key factors affecting tool cutting performance, a tool coordinate system based on the required relief angle and the cutting edge was established. Then, by the proposed tool coordinate system, an algorithm to determine the position between the grinding wheel and the tool is proposed, and then the relevant formulations are deduced. The coordinates of grinding point when the step of relief surface is grinded are calculated.Using the input data of a ball-end mill geometry, wheels geometry, wheel setting and machine setting, the NC code for machining will be generated. Then the code will be used as input to simulate the ball-end mill machining in 3 Dimension before real machining. The algorithm of ball-end mill relief can be authenticated by the 3D simulation system.

Cutter-Workpiece Engagement Calculations by Parallel Slicing for Five-Axis Flank Milling of Jet Engine Impellers

2008 ◽  
Vol 130 (5) ◽  
Author(s):  
W. Ferry ◽  
D. Yip-Hoi
Keyword(s):  
Cutting Forces ◽  
Solid Modeling ◽  
Boundary Representation ◽  
Flank Milling ◽  
Jet Engine ◽  
Current Configuration ◽  
End Mills ◽  
Machining Operations ◽  
Intersection Curves ◽  
Five Axis

Cutter-workpiece engagement maps, or cutting flute entry/exit locations as a function of height, are a requirement for prediction of cutting forces on the tool and workpiece in machining operations such as milling. This paper presents a new method of calculating tool-part intersection maps for the five-axis flank milling of jet engine impellers with tapered ball-end mills. The parallel slicing method (PSM) is a semi-discrete solid modeling technique written in C++ using the ACIS boundary representation solid modeling environment. The tool swept envelope is generated and intersected with the workpiece to obtain the removal volume. It is also subtracted from the workpiece to obtain the finished part. The removal volume is sliced into a number of parallel planes along a given axis, and the intersection curves between each tool move and plane are determined analytically. The swept area between successive tool positions is generated using the common tangent lines between intersection curves, and then removed from the workpiece. This deletes the material cut between tool moves, ensuring correct engagement conditions. Finally, the intersection curves are compared to the planar slices of the updated part, resulting in a series of arcs. The end points of these arcs are joined with linear segments to form the engagement polygon that is used to calculate the engagement maps. Using this method, cutter-workpiece engagement maps are generated for a five-axis flank milling toolpath on a prototype integrally bladed rotor with a tapered ball-end mill. These maps are compared to those obtained from a benchmark cutter-workpiece engagement extraction method, which employs a fast, z-buffer technique. Overall, the PSM appears to obtain more accurate engagement zones, which should result in more accurate prediction of cutting forces. With the method’s current configuration, however, the calculation time is longer.

Development Research of the End Mills Grinding Programming System Based on MATLAB

2013 ◽  
Vol 422 ◽  
pp. 242-246
Author(s):  
Hong Jun Zhang ◽  
Jian Guang Li ◽  
Tian Wei Zhang
Keyword(s):  
Simulation Software ◽  
Cnc Machining ◽  
Programming System ◽  
Development Research ◽  
Machining Simulation ◽  
Nc Code ◽  
Cnc Grinding ◽  
End Mills ◽  
Five Axis ◽  
Grinding Simulation

Using MATLAB for development tools,we has developed a set of end mills CNC grinding programming system by analysis the end mills grinding craft ,research on cutter location trajectory calculation and post-processing technology. Meanwhile, build a five-axis tool grinder grinding simulation processing by VERICUT(a kind of CNC machining simulation software), through the edge grinding simulation , we confirm the cutter location trajectory and the NC code is errorless.

Cutter-Workpiece Engagement Calculations by Parallel Slicing for Five-Axis Flank Milling of Jet Engine Impellers

2007 ◽  
Author(s):  
W. Ferry ◽  
D. Yip-Hoi
Keyword(s):  
Application Programming Interface ◽  
Solid Modeling ◽  
Flank Milling ◽  
Workpiece Material ◽  
Jet Engine ◽  
End Mills ◽  
Slicing Method ◽  
Machining Operations ◽  
Intersection Curves ◽  
Five Axis

Cutter-workpiece engagement maps, or cutting flute entry/exit locations as a function of height, are a requirement for prediction of cutting-forces on the tool and workpiece in machining operations such as milling. This paper presents a new method of calculating tool-part intersection maps for five-axis flank milling of jet engine impellers with tapered ball-end mills. It is called the parallel slicing method (PSM) and is a semi-discrete solid modeling technique written in C++ using the ACIS B-rep solid modeling environment. Although it is tailored towards five-axis flank milling, it can also be applied to both planar and multi-axis milling processes. The tool swept envelope is generated and intersected with the workpiece to obtain the removal volume. The removal volume is then sliced into a number of parallel planes along a given axis and the intersection curves with the tool and each plane are determined analytically. The swept area between the intersection curves of successive tool moves is calculated by solving for the area enclosed by the tangent lines. This area is removed from the workpiece material, which deletes the material cut between tool moves. Finally, the intersection curves are compared with the planar slices of the updated part, which results in a series of arcs. The end points of these arcs are joined with linear segments to form the engagement polygon which is used to calculate the engagement maps. Using this method, cutter-workpiece engagement maps are generated for a five-axis flank milling toolpath on a prototype integrally bladed rotor (IBR) with a tapered ball-end mill. These maps are compared with those obtained from a benchmark cutter-workpiece engagement calculation method – the Manufacturing Automation Laboratory’s Virtual Machining Interface (MAL-VMI). The MAL-VMI uses an application programming interface (API) in a commercial NC verification software package to obtain cutter-part intersections through a fast, z-buffer technique. Overall, the parallel slicing method appears to obtain more accurate engagement zones than those given by the MAL-VMI, although the calculation time is longer.

Parameter Optimization of a Five-Axis Tool Grinder Using Grey Relational Analysis

2010 ◽  
Vol 458 ◽  
pp. 246-251 ◽  
Author(s):  
Jenn Yih Chen ◽  
Bean Yin Lee
Keyword(s):  
Grey Relational Analysis ◽  
End Mill ◽  
Relational Analysis ◽  
Control Factors ◽  
Planning And Design ◽  
End Mills ◽  
Optimal Values ◽  
Inspection Machine ◽  
Grey Relational ◽  
Five Axis

This paper uses the grey relational analysis to find the optimal values of parameters of the servo drives and the controller of a five-axis CNC tool grinder in order to improve precision of grinding and accuracy of end mills. The experimental planning and design are based on the Taguchi method. There are totally six control factors in the experiments, and each factor has three levels. An L18 orthogonal array was applied for the experiments, and each experiment was repeated three times. The grey relational approach was then employed to find the optimal values to the drives and the controller. These values were utilized for grinding a ball nose end mill of cemented tungsten carbide with two-flute and 6 mm in outside diameter. Finally, a well-known tool measuring and inspection machine was used to measure the geometric parameters of the end mill for the initial design and the optimal design. Experimental results show that the grinding time is reduced up to 6.02 ％, and the precision of the ball nose end mill is also improved. Thus, the results demonstrate the effectiveness of the proposed approach.

A Generalized and Efficient Approach for Accurate Five-Axis Flute Grinding of Cylindrical End-Mills

2017 ◽  
Vol 140 (1) ◽  
Author(s):  
Lei Ren ◽  
Shilong Wang ◽  
Lili Yi
Keyword(s):  
Singular Points ◽  
Grinding Process ◽  
Core Radius ◽  
End Mill ◽  
New Approach ◽  
Original Algorithm ◽  
Efficient Approach ◽  
Computer Aided ◽  
End Mills ◽  
Five Axis

Wheel position (including wheel location and orientation) in the flute grinding process of an end-mill determines the ground flute's geometric parameters, i.e., rake angle, core radius, and flute width. Current technologies for calculating the wheel position to guarantee the three parameters' accuracy are either time-consuming or only applicable to the grinding wheels with singular points. In order to cope with this problem, this paper presents a generalized and efficient approach for determining the wheel position accurately in five-axis flute grinding of cylindrical end-mills. A new analytic expression of the wheel location is derived and an original algorithm is developed to search for the required wheel position. This approach can apply not only to the wheels with fillets but also to the wheels with singular points. Simulation examples are provided to validate the new approach and compared with the results from other literature. Besides the ability to determine the wheel position, the new approach can evaluate extrema of the core radius and flute width that a specified wheel can generate. Owing to the evaluated extrema, automatic 1V1 wheel customization according to the designed flute is realized in this paper. This work can improve the efficiency and automation degree of the flute grinding process and lay a good foundation for the development of a comprehensive computer-aided design and computer-aided manufacturing system for end-mill manufacturing.

Using the Flat-End Mill in the Strip Width Machining

2012 ◽  
Vol 723 ◽  
pp. 170-173
Author(s):  
Can Zhao ◽  
Yun Fei Guan ◽  
Yan Yan Guo
Keyword(s):  
Difficult Problem ◽  
Strip Width ◽  
End Mill ◽  
Machining Time ◽  
Surface Machining ◽  
Large Program ◽  
End Mills ◽  
Tool Position ◽  
Five Axis ◽  
Processing Cycle

Surface machining has become a difficult problem in aviation manufacturing, we always using ball-end mills, it is easy to determine the tool position in five-axis machining, but because of the large program, low material remove rate, the processing cycle long, and the surface accuracy is also poor. The paper suggests using the flat-end mill to strip width machining. Using this way, the CNC program is shorter, surface quality is better, the most import is reducing the machining time obviously. Now this method only used in the simple surface, so it requires further research.

Free-Form Flank Correction in Helical Gear Grinding Using a Five-Axis Computer Numerical Control Gear Profile Grinding Machine

2012 ◽  
Vol 134 (4) ◽  
Author(s):  
Yi-Pei Shih ◽  
Shi-Duang Chen
Keyword(s):  
Correction Method ◽  
Computer Numerical Control ◽  
Numerical Control ◽  
Free Form ◽  
Profile Grinding ◽  
Wheel Profile ◽  
Grinding Machine ◽  
Tooth Flank ◽  
Five Axis ◽  
Gear Profile

To reduce form grinding errors, this paper proposes a free-form flank topographic correction method based on a five-axis computer numerical control (CNC) gear profile grinding machine. This correction method is applied not only to the five-axis machine settings (during grinding) but also to the wheel profile (during wheel truing). To achieve free-form modification of the wheel profile, the wheel is formulated as B-spline curves using a curve fitting technique and then normal correction functions made up of four-degree polynomials are added into its working curves. Additionally, each axis of the grinding machine is formulated as a six-degree polynomial. Based on a sensitivity analysis of the polynomial coefficients (normal correction functions and CNC machine settings) on the ground tooth flank and the topographic flank errors, the corrections are solved using the least squares method. The ground tooth flank errors can then be efficiently reduced by slightly adjusting the wheel profile and five-axis movement according to the solved corrections. The validity of this flank correction method for helical gears is numerically demonstrated using the five-axis CNC gear profile grinding machine.

Study on Helical Groove and Circumferential Cutting Edge Machining Simulation of End Mill

2013 ◽  
Vol 589-590 ◽  
pp. 351-356
Author(s):  
Guo Chao Li ◽  
Jie Sun ◽  
Jian Feng Li ◽  
Qing Chun Xiong
Keyword(s):  
3D Model ◽  
Rake Angle ◽  
Cutting Edge ◽  
Machining Simulation ◽  
End Mill ◽  
Inner Radius ◽  
Helical Groove ◽  
End Mills ◽  
Wheel Profile ◽  
The Mathematical Model

A purely analytical method, based on the meshing theory, is presented to establish the exact helical groove and circumferential cutting edge model of end mills, for the solution of its low design precision and efficiency problems. Firstly, a coordinate system to represent the relative space position relations between grinding wheels and end mills is built and the mathematical model of the helical groove is precisely calculated with a given wheel profile and relative movements between the wheel and the workpiece. Then, the rake angle, inner radius and wheel positions of machining the clearance faces is computed. Finally, a 3D model of the end mill is generated by using OpenGL.

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