Tool Path Generation and Manufacturing Process for Blades of a Compressor Rotor
This paper presents a complete procedure for tool path
planning and blade machining in 5-axis manufacturing. The actual
cutting contact and cutter locations can be determined by lead and tilt
angles. The tool path generation is implemented by piecewise curved
approximation and chordal deviation detection. An application about
drive surface method promotes flexibility of tool control and stability
of machine motion. A real manufacturing process is proposed to
separate the operation into three regions with five stages and to modify
the local tool orientation with an interactive algorithm.
[1] E. L. J. Bohez, S. D. R. Senadhera, K. Pole, J. R. Duflou, and T. Tar, "A
geometric modeling and five-axis machining algorithm for centrifugal
impellers," J. Manuf. Syst., vol. 16, pp. 422-436, 1997.
[2] E. Buduk, "Improving productivity and part quality in milling of titanium
based impellers by chatter suppression and force control," Ann. CIRP.,
vol. 49, pp. 31-36, 2000.
[3] T. S Lim, C. M. Lee, S. W. Kim, and D. W. Lee, "Evaluation of cutter
orientations in 5-axis high speed milling of turbine blade," J. Mater.
Process Technol., vol. 130-131, pp. 401-406, Dec. 2002.
[4] C. J. Chiou and Y. S. Lee, "A shape-generating approach for multi-axis
machining G-buffer models," Comput. Aided D., vol. 31, pp. 761-776,
Oct. 1999.
[5] C. G. Jensen, W. E. Red, and J. Pi, "Tool selection for five-axis curvature
matched machining," Comput. Aided D., vol. 34, pp. 251-266, Mar.
2002.
[6] C. S. Jun, K. Cha, and Y. S. Lee, "Optimizing tool orientations for 5-axis
machining by configuration-space search method," Comput. Aided D.,
vol. 35, pp. 549-566, May 2003.
[7] J. Chaves-Jacob , G. Poulachon, and E. Ducb, "New approach to 5-axis
flank milling of free-form surfaces: computation of adapted tool shape,"
Comput. Aided D., vol. 41, pp. 918-929, Dec. 2009.
[8] S. P. Radzevich, "Conditions of proper sculptured surface machining,"
Comput. Aided D., vol. 34, pp. 727-740, Sep. 2002.
[9] P. Gilles, F. Monies, and W. Rubio, "Optimum orientation of a torus
milling cutter: method to balance the transversal cutting force," Int. J.
Mach. Tools Manuf., vol. 47, pp.2263-2272, Dec. 2007.
[10] K. L. Chui, W. K. Chiu, and K. M. Yu, "Direct 5-axis tool-path
generation from point cloud input using 3D biarc fitting," Robot Comput.
Integr. Manuf., vol. 24, pp. 270-286, Apr. 2008.
[11] B. Lauwers, P. Dejonghe, and J. P. Kruth, "Optimal and collision free tool
posture in five-axis machining through the tight integration of tool path
generation and machine simulation," Comput. Aided D., vol. 35, pp.
421-432, Apr. 2003.
[12] E. Ozturk, L. T. Tunc, and E. Budak, "Investigation of lead and tilt angle
effects in 5-axis ball-end milling processes," Int. J. Mach. Tools Manuf.,
vol. 49, pp. 1053-1062, Nov. 2009.
[13] J. Denavit and R. S. Hartenberg, "A kinematic notation for lower-pair
mechanisms based on matrices," J. Appl. Mech., vol. 22, pp. 215-221,
1955.
[14] B. K. Choi and R. B. Jerard, Sculptured Surface Machining Theory and
Applications, Kulwer Academic, 1998, pp. 26-30.
[15] G. Erdos, M. Muller, and P. Xirouchakis, "Parametric tool correction
algorithm for 5-axis machining," Adv. Eng. Softw., vol. 36, pp. 654-663,
Oct. 2005.
[16] E. L. J. Bohez, "Five-axis milling machine tool kinematic chain design
and analysis," Int. J. Mach. Tools Manuf., vol. 42, pp. 505-520, Mar.
2002.
[17] C. Tung and P. L. Tso, "Inverse kinematics with 3-dimensational tool
compensation for 5-axis machine center of tilting rotary table," 2011 2nd
Int. Conf. MIMT, Singapore, Feb., to be published.
[18] DIN, DIN 66215: CLDATA. NC-Maschinen, Berlin, Beuth Verlage,
1987.
[19] C. Tung and P. L. Tso, "A generalized cutting location expression and
postprocessors for multi-axis machine centers with tool compensation,"
Int. J. Adv. Manuf. Technol., vol. 50, pp. 1113-1123, Oct. 2010.
[20] L. Piegl and W. Tiller, The NURBS Book, Springer, 1995.
[21] T. C. Chang, R. A. Wysk, and H. P. Wang, Computer-Aided
Manufacturing, 2nd ed., Prentice Hall, 1998, pp. 369-378.
[22]
C. Castagnetti, E. Duc, and P. Ray, "The domain of admissible
orientation concept: a new method for five-axis tool path optimisation,"
Comput. Aided D., vol. 40, pp. 938-950, Sep. 2008.
[23] R. Gian, T. W. Lin, and A. C. Lin, "Planning of tool orientation for
five-axis cavity machining," Int. J. Adv. Manuf. Technol., vol. 22, pp.
150-160, Sep. 2003.
[24] Y. K. Choi, A. Banerjee, and J. W. Lee, "Tool path generation for free
form surface using Bézier curves/surfaces," Comput. Ind. Eng., vol. 52,
pp. 486-501, May 2007.
[25] H. Gong and N. Wang, "Optimize tool paths of flank milling with generic
cutters based on approximation using the tool envelope surface," Comput.
Aided D., vol. 41, pp. 981-989, Dec. 2009.
[26] S. Austin, R. B. Jerard, and S. Drysdale, "Comparison of discretization
algorithms for NURBS surfaces with application to numerically
controlled machining," Comput. Aided D., vol. 29, pp. 71-83, Jan. 1997.
[1] E. L. J. Bohez, S. D. R. Senadhera, K. Pole, J. R. Duflou, and T. Tar, "A
geometric modeling and five-axis machining algorithm for centrifugal
impellers," J. Manuf. Syst., vol. 16, pp. 422-436, 1997.
[2] E. Buduk, "Improving productivity and part quality in milling of titanium
based impellers by chatter suppression and force control," Ann. CIRP.,
vol. 49, pp. 31-36, 2000.
[3] T. S Lim, C. M. Lee, S. W. Kim, and D. W. Lee, "Evaluation of cutter
orientations in 5-axis high speed milling of turbine blade," J. Mater.
Process Technol., vol. 130-131, pp. 401-406, Dec. 2002.
[4] C. J. Chiou and Y. S. Lee, "A shape-generating approach for multi-axis
machining G-buffer models," Comput. Aided D., vol. 31, pp. 761-776,
Oct. 1999.
[5] C. G. Jensen, W. E. Red, and J. Pi, "Tool selection for five-axis curvature
matched machining," Comput. Aided D., vol. 34, pp. 251-266, Mar.
2002.
[6] C. S. Jun, K. Cha, and Y. S. Lee, "Optimizing tool orientations for 5-axis
machining by configuration-space search method," Comput. Aided D.,
vol. 35, pp. 549-566, May 2003.
[7] J. Chaves-Jacob , G. Poulachon, and E. Ducb, "New approach to 5-axis
flank milling of free-form surfaces: computation of adapted tool shape,"
Comput. Aided D., vol. 41, pp. 918-929, Dec. 2009.
[8] S. P. Radzevich, "Conditions of proper sculptured surface machining,"
Comput. Aided D., vol. 34, pp. 727-740, Sep. 2002.
[9] P. Gilles, F. Monies, and W. Rubio, "Optimum orientation of a torus
milling cutter: method to balance the transversal cutting force," Int. J.
Mach. Tools Manuf., vol. 47, pp.2263-2272, Dec. 2007.
[10] K. L. Chui, W. K. Chiu, and K. M. Yu, "Direct 5-axis tool-path
generation from point cloud input using 3D biarc fitting," Robot Comput.
Integr. Manuf., vol. 24, pp. 270-286, Apr. 2008.
[11] B. Lauwers, P. Dejonghe, and J. P. Kruth, "Optimal and collision free tool
posture in five-axis machining through the tight integration of tool path
generation and machine simulation," Comput. Aided D., vol. 35, pp.
421-432, Apr. 2003.
[12] E. Ozturk, L. T. Tunc, and E. Budak, "Investigation of lead and tilt angle
effects in 5-axis ball-end milling processes," Int. J. Mach. Tools Manuf.,
vol. 49, pp. 1053-1062, Nov. 2009.
[13] J. Denavit and R. S. Hartenberg, "A kinematic notation for lower-pair
mechanisms based on matrices," J. Appl. Mech., vol. 22, pp. 215-221,
1955.
[14] B. K. Choi and R. B. Jerard, Sculptured Surface Machining Theory and
Applications, Kulwer Academic, 1998, pp. 26-30.
[15] G. Erdos, M. Muller, and P. Xirouchakis, "Parametric tool correction
algorithm for 5-axis machining," Adv. Eng. Softw., vol. 36, pp. 654-663,
Oct. 2005.
[16] E. L. J. Bohez, "Five-axis milling machine tool kinematic chain design
and analysis," Int. J. Mach. Tools Manuf., vol. 42, pp. 505-520, Mar.
2002.
[17] C. Tung and P. L. Tso, "Inverse kinematics with 3-dimensational tool
compensation for 5-axis machine center of tilting rotary table," 2011 2nd
Int. Conf. MIMT, Singapore, Feb., to be published.
[18] DIN, DIN 66215: CLDATA. NC-Maschinen, Berlin, Beuth Verlage,
1987.
[19] C. Tung and P. L. Tso, "A generalized cutting location expression and
postprocessors for multi-axis machine centers with tool compensation,"
Int. J. Adv. Manuf. Technol., vol. 50, pp. 1113-1123, Oct. 2010.
[20] L. Piegl and W. Tiller, The NURBS Book, Springer, 1995.
[21] T. C. Chang, R. A. Wysk, and H. P. Wang, Computer-Aided
Manufacturing, 2nd ed., Prentice Hall, 1998, pp. 369-378.
[22]
C. Castagnetti, E. Duc, and P. Ray, "The domain of admissible
orientation concept: a new method for five-axis tool path optimisation,"
Comput. Aided D., vol. 40, pp. 938-950, Sep. 2008.
[23] R. Gian, T. W. Lin, and A. C. Lin, "Planning of tool orientation for
five-axis cavity machining," Int. J. Adv. Manuf. Technol., vol. 22, pp.
150-160, Sep. 2003.
[24] Y. K. Choi, A. Banerjee, and J. W. Lee, "Tool path generation for free
form surface using Bézier curves/surfaces," Comput. Ind. Eng., vol. 52,
pp. 486-501, May 2007.
[25] H. Gong and N. Wang, "Optimize tool paths of flank milling with generic
cutters based on approximation using the tool envelope surface," Comput.
Aided D., vol. 41, pp. 981-989, Dec. 2009.
[26] S. Austin, R. B. Jerard, and S. Drysdale, "Comparison of discretization
algorithms for NURBS surfaces with application to numerically
controlled machining," Comput. Aided D., vol. 29, pp. 71-83, Jan. 1997.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:53897", author = "C. Tung and P.-L. Tso", title = "Tool Path Generation and Manufacturing Process for Blades of a Compressor Rotor", abstract = "This paper presents a complete procedure for tool path
planning and blade machining in 5-axis manufacturing. The actual
cutting contact and cutter locations can be determined by lead and tilt
angles. The tool path generation is implemented by piecewise curved
approximation and chordal deviation detection. An application about
drive surface method promotes flexibility of tool control and stability
of machine motion. A real manufacturing process is proposed to
separate the operation into three regions with five stages and to modify
the local tool orientation with an interactive algorithm.", keywords = "5-axis machining, tool orientation, lead and tilt angles,tool path generation.", volume = "5", number = "4", pages = "778-6", }
