Calculation and Optimization of Cutter Position for Flank Milling Spatial Cam Based on NURBS

2008 ◽  
Vol 375-376 ◽  
pp. 578-582
Author(s):  
Rong Yu Ge ◽  
Xian Ying Feng ◽  
Xian Chun Song
Keyword(s):  
Tool Path ◽  
Optimization Method ◽  
Least Square ◽  
Flank Milling ◽  
Normal Vector ◽  
Machining Error ◽  
Cam Mechanism ◽  
Tool Axis ◽  
Milling Method ◽  
Tool Axis Vector

In some cases the spatial cam is manufactured with a cutter whose diameter is smaller than that of the roller of cam mechanism, which is defined as nonequivalent manufacture method in the paper. By the analysis for manufacture of contact lines between the cam and the roller, it is indicated that errors caused by the different directions of normal vector are unavoidable for the nonequivalent manufacture method. In order to find the best tool axis vector to minimize the machining error, this paper realized the nonequivalent machining of spatial cam surfaces using the NC flank milling method and proposed a new generation algorithm of the tool path based on NURBS. The NURBS ruled surface of tool axis trajectory is confirmed based on the least square optimization method and the machining error model is given. At last, a numerical calculation and simulation example is described to verify the effectiveness of the algorithm proposed in the paper.

Nonequivalent Milling of Roller Gear Cams Based on Approximation Method of Offset Surface

2010 ◽  
Vol 97-101 ◽  
pp. 1998-2001
Author(s):  
Rong Yu Ge ◽  
Xian Ying Feng ◽  
Pei Quan Guo
Keyword(s):  
Approximation Method ◽  
Least Square ◽  
Control Points ◽  
Machining Error ◽  
Theoretical Tool ◽  
Tool Axis ◽  
Milling Method ◽  
Tool Position ◽  
Tool Axis Vector ◽  
Offset Surface

The roller gear cam surface is manufactured with nonequivalent milling method in many cases, by which the machining error is unavoidable. In order to simplify the tool position, we can transform one problem approximating the designed surface with the tool envelope surface to another problem approaching the theoretical tool axis trajectory surface with the actual one. Furthermore, the theoretical tool axis trajectory surface, which is an offset surface of the designed cam surface, is reconstructed by the NURBS ruled surface. In order to find the best tool axis vector to minimize the machining error, a simple least square approximation method is established to figure out all the control points of the NURBS tool axis trajectory surface. A numerical calculation and simulation example is described to verify the effectiveness of the tool position method proposed in the paper.

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.

Research on Cutter Location Optimization of Tapered Ball End Mill Finish Flank Milling Ruled Surface Blade

2013 ◽  
Vol 589-590 ◽  
pp. 421-426
Author(s):  
Shuo An ◽  
Yao Nan Cheng ◽  
Xian Li Liu ◽  
Mao Yue Li ◽  
Lei Shi
Keyword(s):  
Optimization Method ◽  
Ruled Surface ◽  
Flank Milling ◽  
End Mill ◽  
Ball End Mill ◽  
Location Optimization ◽  
Envelope Surface ◽  
Tool Axis ◽  
Low Efficiency ◽  
Tool Axis Vector

For the low efficiency and poor surface quality problem of finishing ruled surface blade in the traditional method, tapered ball end mill cutter location optimization methods had been proposed to ensure that the envelope surface of tapered ball end mill is close to intractable ruled surface blade as much as possible. First, the tapered ball end mill initial cutter location was obtained based on the improved two point offset algorithm. Then to realize the cutter location optimization calculation, selected three point in tool axis to slide for the target of the minimum range between cutter envelope surface and blade surface. Finally, the blades instance was calculated according to the obtained tool center point and optimized tool axis vector. Simulation and experiments verified the effectiveness of cutter location optimization method proposed in this paper.

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.

Analysis and Compensation Strategy of Non-Linear Error in Five-Axis CNC Machining

2014 ◽  
Vol 644-650 ◽  
pp. 4967-4970 ◽  
Author(s):  
Hong Jun Liu ◽  
Ai Guo Zhang ◽  
Ji Bin Zhao ◽  
Jin Shang ◽  
Jun Liu
Keyword(s):  
Complex Surface ◽  
Cnc Machining ◽  
Machining Accuracy ◽  
Machining Error ◽  
Tool Axis ◽  
Non Linear ◽  
New Strategy ◽  
Tool Position ◽  
Five Axis ◽  
Tool Axis Vector

This paper presents a new strategy of analysis and compensation of non-linear error. Non-linear error is an important source of machining error in multi-axis numerical controlled machining and it is unavoidable. In view of tool positions optimization in five-axis CNC machining of complex surface, this paper presents a strategy for non-linear error compensation in five-axis machining: Firstly, non-linear error caused by the change of tool axis vector is analyzed and the non-linear error model is established, in order to get the maximum non-linear error of interpolation segment; Then, the tool position that meets the machining accuracy is obtained; Finally, Simulation and analysis of the model show that the proposed method is effective and greatly improves the geometric accuracy.

Tool Path Planning for Five-Axis NC Machining of Implant Shaping Mold for Cranioplasty

2011 ◽  
Vol 697-698 ◽  
pp. 292-296
Author(s):  
Liang Zhang ◽  
J. Li ◽  
B.C. Lou
Keyword(s):  
Path Planning ◽  
Tool Path ◽  
Nc Machining ◽  
Normal Curvature ◽  
Tool Path Planning ◽  
Lead Angle ◽  
Tool Axis ◽  
Nc Machine ◽  
Five Axis ◽  
Tool Axis Vector

The necessity for skull patch surface for cranioplasty was introduced and it was divided according to maximum normal curvature in the discrete points after skull patch surface dispersed. Then the tool axis vector was determined by the lead angle of the tool, corresponding to generating the tool path in each area; At last, the implant shaping mold for cranioplasty was produced by five-axis NC machine.

scholarly journals A Study on Interferential Tool Position Correcting Algorithm in Rough Machining of 3d Impeller Variable-axis Plunge Milling

2021 ◽  
Author(s):  
Lei Dong ◽  
Jie Wang
Keyword(s):  
Tool Path ◽  
Contact Point ◽  
Normal Vector ◽  
Sudden Increase ◽  
Rough Machining ◽  
Plunge Milling ◽  
Radial Depth ◽  
Milling Method ◽  
Tool Position ◽  
Cutter Position

Abstract The plunge milling method has remarkably improved the rough machining efficiency of 3D impeller channel. However, in conventional cutter position planning for plunge milling, interference at the end of every cutter position due to sudden increase of radial depth is inevitable, which may seriously compromise the service life of machine tool and cutter, as well as the cutting efficiency at the interferential phase. This study optimized the cutter axis vector for the tool path of conventional rough machining of 3D impeller variable -axis plunge milling to make the angle between the normal vector for workpiece surface at the cutter contact point and the cutter-axis vector of adjacent tool position increase gradually from outlet to inlet at the smallest scale. Based on this, an iterative algorithm for tool center position and safety height for the cutter was provided, thus making the hub allowance of the optimized tool path for plunge milling as small as possible without affecting the subsequent machining on the premise of avoiding the interferential phenomenon. Finally, the correctness of the proposed method was verified by relevant numerical examples.

Optimized Tool Path Planning for Five-Axis Flank Milling of Ruled Surface Considering Tolerance

2012 ◽  
Vol 472-475 ◽  
pp. 114-118
Author(s):  
Jun Feng Tian ◽  
Hu Lin ◽  
Zhuang Yao ◽  
Jie Li
Keyword(s):  
Path Planning ◽  
Tool Path ◽  
Critical Issue ◽  
Flank Milling ◽  
Tool Path Planning ◽  
Machining Error ◽  
Tool Paths ◽  
Global And Local Optimization ◽  
Global And Local ◽  
Five Axis

Five-axis CNC flank milling has recently received much attention in industry. Tool path planning is a critical issue in five-axis CNC flank milling operation. Previous work based on dynamic-programming generated optimal tool path by global minimising the machining error. However, global minimal machining error may not guarantee a local machining error controllable. Therefore, this paper proposes a method based on combination of global and local optimization, which makes tool path of five-axis flank milling optimal and error controllable. Oversize error of tool paths can be partially adjusted so that a specified tolerance is met in global optimization processing. Finally, the experiments of the simulative are made by this algorithm. The result verifies the feasibility and validity of the proposed scheme.

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