Five-Axis Flank Milling Method of Plane Double Enveloping Hourglass Worm

2011 ◽  
Vol 314-316 ◽  
pp. 1523-1532
Author(s):  
Lei Zhong ◽  
Qing Zhen Bi ◽  
Yu Han Wang ◽  
Han Ding
Keyword(s):  
Surface Quality ◽  
Tool Path ◽  
End Milling ◽  
Tooth Surface ◽  
Flank Milling ◽  
Machining Efficiency ◽  
Contact Lines ◽  
Milling Method ◽  
Simulation And Experiment ◽  
Five Axis

A high-precision and efficient machining method of plane double enveloping hourglass worm is proposed. The worm tooth surface is first created and analyzed based on meshing theory. The analysis reveals that the worm tooth surface is a developable ruled surface. This provides the ability of precise flank milling of the worm tooth surface. The meshing lines on the worm tooth surface indicate the contact lines of the worm tooth and the cutter. The five-axis tool path of flank milling is then generated according to the meshing lines. The flank milling has obviously advantages in machining efficiency and surface quality, compared with the conventional end milling method. The cutting simulation and experiment validate proposed method.

scholarly journals Cutting force and machine kinematics constrained cutter location planning for five-axis flank milling of ruled surfaces

2017 ◽  
Vol 4 (3) ◽  
pp. 203-217 ◽  
Author(s):  
Ke Xu ◽  
Jiarui Wang ◽  
Chih-Hsing Chu ◽  
Kai Tang
Keyword(s):  
Cutting Force ◽  
Surface Quality ◽  
Feed Rate ◽  
Tool Path ◽  
Flank Milling ◽  
Machining Efficiency ◽  
Location Planning ◽  
Tool Positioning ◽  
Finished Surface ◽  
Five Axis

Abstract Five-axis flank milling has been commonly used in the manufacturing of complex workpieces because of its greater productivity than that of three-axis or five-axis end milling. The advantage of this milling operation largely depends on effective cutter location planning. The finished surface sometimes suffers from large geometrical errors induced by improper tool positioning, due to the non-developability of most ruled surfaces in industrial applications. In addition, a slender flank-milling cutter may be deflected when subjected to large cutting forces during the machining process, further degrading the surface quality or even breaking the cutter. This paper proposes a novel tool path planning scheme to address those problems. A simple but effective algorithm is developed to adaptively allocate a series of cutter locations over the design surface with each one being confined within an angular rotation range. The allocation result satisfies a given constraint of geometrical errors on the finished surface, which consists of the tool positioning errors at each cutter location and the sweeping errors between consecutive ones. In addition, a feed rate scheduling algorithm is proposed to maximize the machining efficiency subject to the cutting force constraint and the kinematical constraints of a specific machine configuration. Simulation and experimental tests are conducted to validate the effectiveness of the proposed algorithms. Both the machining efficiency and finish surface quality are greatly improved compared with conventional cutter locations. Highlights Tool position is bounded with respect to the geometrical machining error. Cutting force and kinematics during five-axis flank milling process are analyzed. An incremental adaptive flank milling tool path generation algorithm is proposed. Feed rate is smoothly assigned respecting cutting force and kinematic constraints.

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.

Effect of Tool Inclination Angle on Surface Quality in 5-Axis Ball-End Milling

2010 ◽  
Vol 97-101 ◽  
pp. 2080-2084 ◽  
Author(s):  
Shi Guo Han ◽  
Jun Zhao
Keyword(s):  
Surface Quality ◽  
Inclination Angle ◽  
End Milling ◽  
Milling Process ◽  
Cutting Condition ◽  
Ball End Milling ◽  
Inclination Angles ◽  
Milling Method ◽  
Five Axis ◽  
Tool Axis Vector

Because of the complexity of five-axis ball-end milling process, it is difficult to control the quality of the finished parts. It is well known that one of the most important differences between 5-axis and 3-axis CNC machining is whether tool-axis vector is variable in milling process. In this paper, the tool orientation is researched in order to obtain desired surface quality and improve production efficiency. And the influence of tool inclination angle on surface integrity, especially surface topography/roughness and residual stress in high-speed milling of P20 die steel is studied by means of milling experiments including 8 cases of ball-end milling of freeform surface. Finally, the optimal tool inclination angles including lead angle and tilt angle and milling method were obtained for 5-axis ball-end milling. And in the meanwhile, cutting condition can be improved and better surface quality can be obtained by selecting reasonable tool inclination angles and up/down milling method.

scholarly journals An Efficient Approach to the Five-Axis Flank Milling of Non-Ferrous Spiral Bevel Gears

Materials ◽  
2021 ◽  
Vol 14 (17) ◽  
pp. 4848
Author(s):  
Hao Xu ◽  
Yuansheng Zhou ◽  
Yuhui He ◽  
Jinyuan Tang
Keyword(s):  
Contact Area ◽  
Tool Path ◽  
Closed Form Solution ◽  
Tooth Surface ◽  
Flank Milling ◽  
Machining Accuracy ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Spiral Bevel ◽  
Five Axis

Five-axis flank milling has been applied in industry as a relatively new method to cut spiral bevel gears (SBGs) for its flexibility, especially for the applications of small batches and repairs. However, it still has critical inferior aspects compared to the traditional manufacturing ways of SBGs: the efficiency is low, and the machining accuracy may not ensure the qualified meshing performances. To improve the efficiency, especially for cutting non-ferrous metals, this work proposes an approach to simultaneously cut the tooth surface and tooth bottom by a filleted cutter with only one pass. Meanwhile, the machining accuracy of the contact area is considered beforehand for the tool path optimization to ensure the meshing performances, which is further confirmed by FEM (finite element method). For the convenience of the FEM, the tooth surface points are calculated with an even distribution, and the calculation process is efficiently implemented with a closed-form solution. Based on the proposed method, the number (or total length) of the tool path is reduced, and the contact area is qualified. Both the simulation and cutting experiment are implemented to validate the proposed method.

Researches on the Measurement Rebuilding and Multi-Axis Flank Milling NC Machining of the Compressor Impeller

2014 ◽  
Vol 625 ◽  
pp. 241-246 ◽  
Author(s):  
Wei Fang Chen ◽  
Jui Te Chang ◽  
Jia Hong Su
Keyword(s):  
End Milling ◽  
Rapid Development ◽  
Nc Machining ◽  
Ruled Surfaces ◽  
Flank Milling ◽  
Machining Efficiency ◽  
Nc Code ◽  
Rule Surface ◽  
Five Axis ◽  
Offset Curve

The ruled surface of impeller is widely used in the industry of automobile, shipbuilding, aerospace and aeronautics. Researches on the manufacture of blade possess general meaning. The importance of their performance in the certain field and the non-replace ability of their functions in the specified mechanical systems have resulted in that the technology of manufacturing and measurement for ruled surfaces has been a critical research project in the field of dimensional manufacturing and measurements. With the rapid development of the modern science and technology, complex ruled surfaces are employed more and more widely, but their tolerances become narrower and narrower. The common impeller surfaces represented by NURBS are given and then curve and surface interpolation algorithm represented by NURBS are presented. These provide theoretical foundation for NC machining programming of impeller surface. Principals of normal offset curve and inclined offset surface are used to simplify the model. The NC milling method of divide area is presented to raise machining efficiency and to improve quality of machined surface. The machining efficiency is important in line property of rule surface, flank milling rule surface with end-milling, improve surface quality and cutter efficiency. This paper presents a calculate method to generate five-axis flank milling NC code of divide area in the blade of compressor with Vericut simulating the five-axis flank milling NC code and measurement the result of processing that verification the precision of five-axis flank milling. This paper also simulates four-axis machining for comparing cutting efficiency between five-axis machining and four-axis machining and the status of both the great differences in processing efficiency.

Global optimization of tool path for five-axis flank milling with a conical cutter

2010 ◽  
Vol 42 (10) ◽  
pp. 903-910 ◽  
Author(s):  
LiMin Zhu ◽  
Gang Zheng ◽  
Han Ding ◽  
YouLun Xiong
Keyword(s):  
Global Optimization ◽  
Tool Path ◽  
Flank Milling ◽  
Five Axis

scholarly journals Optimisation of Planning Parameters for Machining Blade Electrode Micro-Fillet with Scallop Height Modelling

Micromachines ◽  
2021 ◽  
Vol 12 (3) ◽  
pp. 237
Author(s):  
Yue Liu ◽  
Zhanqiang Liu ◽  
Wentong Cai ◽  
Yukui Cai ◽  
Bing Wang ◽  
...  
Keyword(s):  
Path Planning ◽  
Tilt Angle ◽  
Tool Path ◽  
End Milling ◽  
Tool Path Planning ◽  
Scallop Height ◽  
Aero Engine ◽  
Tool Tilt Angle ◽  
Five Axis ◽  
Height Model

Aero-engine blades are manufactured by electroforming process with electrodes. The blade electrode is usually machined with five-axis micromilling to get required profile roughness. Tool path planning parameters, such as cutting step and tool tilt angle, have a significant effect on the profile roughness of the micro-fillet of blade electrode. In this paper, the scallop height model of blade electrode micro-fillet processed by ball-end milling cutter was proposed. Effects of cutting step and tool tilt angle the machined micro-fillet profile roughness were predicted with the proposed scallop height model. The cutting step and tool tilt angle were then optimised to ensure the contour precision of the micro-fillet shape requirement. Finally, the tool path planning was generated and the machining strategy was validated through milling experiments. It was also found that the profile roughness was deteriorated due to size effect when the cutting step decreased to a certain value.

Tool Path Planning for Five-Axis U-Pass Milling of an Impeller

2021 ◽  
Author(s):  
J.Y. Feng ◽  
Z.C. Wei ◽  
M.J. Wang ◽  
X.Q. Wang ◽  
M.L. Guo
Keyword(s):  
Path Planning ◽  
Cutting Force ◽  
Tool Path ◽  
Flank Milling ◽  
Small Range ◽  
Tool Path Planning ◽  
Point Distribution ◽  
Parameter Domain ◽  
Five Axis ◽  
Tool Axis Vector

Abstract U-pass milling is a roughing method that combines the characteristics of flank milling with conventional trochoidal milling. The tool cuts in and out steadily, and the tool–workpiece wrap angle is maintained within a small range. This method can smooth the cutting force and reduce the peak cutting force while avoiding cutting heat accumulation, which can significantly improve the processing efficiency and reduce tool wear. In this study, a tool path model is established for U-pass milling, and the characteristic parameters of the path are defined. Through a comparative test of three-axis groove milling, it is demonstrated that the peak value and average value of the cutting force are reduced by 25% and 60%, respectively. An impeller runner is considered as the processing object, and the milling boundary parameters are pretreated. A tiling micro-arc mapping algorithm is proposed, which maps the three-dimensional boundary to the two-dimensional parameter domain plane with the arc length as the coordinate axis, and the dimensionally reduced tool contact point distribution form is obtained. The geometric domain tool position point and the interference-free tool axis vector are obtained by calculating the bidirectional proportional domain of the runner and the inverse mapping of any vector in the parameter domain. Finally, the calculation results are nested into the automatically programmed tool (APT) encoding form, and the feasibility of the five-axis U-pass milling tool path planning method is verified through a numerical example.

Sign in / Sign up

Export Citation Format

Share Document