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.

Research on Five-Axis Dual-NURBS Adaptive Interpolation Algorithm for Flank Milling

2010 ◽  
Vol 443 ◽  
pp. 330-335 ◽  
Author(s):  
Yu Han Wang ◽  
Jing Chun Feng ◽  
Sun Chao ◽  
Ming Chen
Keyword(s):  
Tool Path ◽  
Flank Milling ◽  
Interpolation Algorithm ◽  
Machining Time ◽  
Surface Machining ◽  
Tool Axis ◽  
Scanning Area ◽  
Nurbs Interpolation ◽  
Milling Method ◽  
Five Axis

In order to exploit the advantages of five-axis flank milling method for space free surface machining to the full, a definition of non-equidistant dual-NURBS tool path is presented first. On this basis, the constraint of velocity of points on the tool axis and the constraint of scanning area of the tool axis are deduced. Considering both of these constraints, an adaptive feed five-axis dual-NURBS interpolation algorithm is proposed. The simulation results show that the feedrate with the proposed algorithm satisfies both of the constraints and the machining time is reduced by 38.3% in comparison with the constant feed interpolator algorithm.

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.

A novel tool-path generation method for five-axis flank machining of centrifugal impeller with arbitrary surface blades

2016 ◽  
Vol 231 (1) ◽  
pp. 155-166 ◽  
Author(s):  
Hong-Zhou Fan ◽  
Shang-Jin Wang ◽  
Guang Xi ◽  
Yan-Long Cao
Keyword(s):  
Tool Path ◽  
Tool Path Generation ◽  
Ruled Surface ◽  
Centrifugal Impeller ◽  
Flank Milling ◽  
Path Generation ◽  
Rough Machining ◽  
Machining Time ◽  
Geometrical Structures ◽  
Five Axis

The centrifugal impeller with arbitrary surface blades is a very important component in automobile, ships, and aircraft industry, and it is one of the most difficult parts to process. Focusing on the machining efficiency improvement, combining the geometric advantages of ruled surface and arbitrary surface, and utilizing the efficient and accurate advantages of flank machining and point machining, this article presents a novel and targeted tool-path generation method and algorithm for five-axis flank machining of centrifugal impeller with arbitrary surface blades. In light of specific characters of different surfaces, the analyses of two different impeller blades are proposed first, the more characteristic and complex geometrical structures of the arbitrary blade are achieved. In rough machining, an approximate ruled surface blade is obtained, and a simple channel is achieved; the flank milling of the centrifugal impeller with ruled surface blades is achieved relative to the point milling of the centrifugal impeller with arbitrary surface blades; and the triangle tool path planning method is added in this process to save the machining time and cost collectively. Furthermore, in semi-finish machining, the approximate sub-ruled blade surfaces are calculated, and a new flank milling method of the sub-ruled blade surfaces is achieved; a new solution for tool interference is achieved in this process and the generation of non-interference tool paths becomes easy. Machining experiments of two different impellers are presented as a test of the proposed methods.

A discrete simulation-based algorithm for the technological investigation of 2.5D milling operations

2018 ◽  
Vol 233 (1) ◽  
pp. 78-90 ◽  
Author(s):  
Adam Jacso ◽  
Tibor Szalay ◽  
Juan Carlos Jauregui ◽  
Juvenal Rodriguez Resendiz
Keyword(s):  
Tool Path ◽  
Analytical Description ◽  
Machining Process ◽  
Simulation Algorithm ◽  
Tool Paths ◽  
Milling Operations ◽  
Nc Simulation ◽  
2.5D Milling ◽  
Milling Tool ◽  
Nc Milling

Many applications are available for the syntactic and semantic verification of NC milling tool paths in simulation environments. However, these solutions – similar to the conventional tool path generation methods – are generally based on geometric considerations, and for that reason they cannot address varying cutting conditions. This paper introduces a new application of a simulation algorithm that is capable of producing all the necessary geometric information about the machining process in question for the purpose of further technological analysis. For performing such an analysis, an image space-based NC simulation algorithm is recommended, since in the case of complex tool paths it is impossible to provide an analytical description of the process of material removal. The information obtained from the simulation can be used not only for simple analyses, but also for optimisation purposes with a view to increasing machining efficiency.

scholarly journals 5-Axis Double-Flank CNC Machining of Spiral Bevel Gears via Custom-Shaped Milling Tools – Part II: Physical Validations and Experiments

2021 ◽  
Author(s):  
Gaizka Gómez Escudero ◽  
Pengbo Bo ◽  
Haizea González Barrio ◽  
Amaia Calleja Ochoa ◽  
Michael Barton ◽  
...  
Keyword(s):  
End Milling ◽  
Bevel Gear ◽  
Cnc Machining ◽  
Flank Milling ◽  
Spiral Bevel Gear ◽  
Machining Accuracy ◽  
Machining Time ◽  
Milling Tool ◽  
Gear Manufacturing ◽  
Spiral Bevel

Abstract We investigate a recently introduced methodology for 5-axis flank computer numerically controlled (CNC) machining, called double-flank milling. Certain geometries, such as curved teeth of spiral bevel gear, admit this approach where the milling tool has tangential contact with the material block on two sides, yielding a more efficient variant of flank milling. To achieve high machining accuracy, the path-planning algorithm, however, does not look only for the path of the tool, but also for the shape of the tool itself. We validate the approach by series of physical experiments using an abrasive custom-shaped milling tool specifically designed for a particular type of a spiral bevel gear. We show the potential of this new methodology in the semifinishing stage of gear manufacturing, where it outperforms traditional ball end milling by an order of magnitude in terms of machining time, while keeping, or even improving, the machining error.

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.

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.

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