Five-axis Strip Machining with Barrel Cutter Based On Tolerance Constraint for Sculptured Surfaces
Taking the design tolerance into account, this paper
presents a novel efficient approach to generate iso-scallop tool path for
five-axis strip machining with a barrel cutter. The cutter location is
first determined on the scallop surface instead of the design surface,
and then the cutter is adjusted to locate the optimal tool position based
on the differential rotation of the tool axis and satisfies the design
tolerance simultaneously. The machining strip width and error are
calculated with the aid of the grazing curve of the cutter. Based on the
proposed tool positioning algorithm, the tool paths are generated by
keeping the scallop height formed by adjacent tool paths constant. An
example is conducted to confirm the validity of the proposed method.
[1] Mullins S, Jensen C, Anderson D (1993) Scallop elimination based on
precise 5-axis tool placement, orientation, and step-over calculations.
ASME Adv Des Autom 65:535-544.
[2] Jensen C, Anderson D (1993) Accurate tool placement and orientation for
finish surface machining. Journal of Design and Manufacturing
59:127-127
[3] Rao N, Ismail F, Bedi S (1997) Tool path planning for five-axis
machining using the principal axis method. International Journal of
Machine Tools and Manufacture 37 (7):1025-1040
[4] Bedi S, Gravelle S, Chen Y (1997) Principal curvature alignment
technique for machining complex surfaces. Journal of manufacturing
science and engineering 119 (4B):756-765
[5] Rao N, Bedi S, Buchal R (1996) Implementation of the principal-axis
method for machining of complex surfaces. The International Journal of
Advanced Manufacturing Technology 11 (4):249-257
[6] Wang X, Wu X, Li Y (1992) Curvature catering—a new concept for
machining sculptured surfaces. Journal of Xi’an Jiaotong University 26
(5):51-58
[7] Gong H, Cao LX, Liu J (2008) Second order approximation of tool
envelope surface for 5-axis machining with single point contact.
Computer-Aided Design 40 (5):604-615
[8] Zhu LM, Ding H, Xiong YL (2010) Third-order point contact approach
for five-axis sculptured surface machining using non-ball-end tools (I):
Third-order approximation of tool envelope surface. SCIENCE CHINA
Technological Sciences 53 (7):1904-1912
[9] Zhu LM, Ding H, Xiong YL (2010) Third-order point contact approach
for five-axis sculptured surface machining using non-ball-end tools (II):
Tool positioning strategy. SCIENCE CHINA Technological Sciences 53
(8):2190-2197
[10] Warkentin A, Ismail F, Bedi S (2000) Multi-point tool positioning
strategy for 5-axis mashining of sculptured surfaces. Computer Aided
Geometric Design 17 (1):83-100
[11] Warkentin A, Ismail F, Bedi S (2000) Comparison between multi-point
and other 5-axis tool positioning strategies. International Journal of
Machine Tools and Manufacture 40 (2):185-208
[12] Gray P, Bedi S, Ismail F (2003) Rolling ball method for 5-axis surface
machining. Computer-Aided Design 35 (4):347-357
[13] Gray PJ, Bedi S, Ismail F (2005) Arc-intersect method for 5-axis tool
positioning. Computer-Aided Design 37 (7):663-674
[14] Zhang H (1987) The developing trend of sculptured surface machining in
increasing the strip width and decrease the scallop height. Surface
Machining and Checking
[15] Wang D, Chen WY, Li T, Xu RF (2009) Five-Axis Flank Milling of
Sculptured Surface with Barrel Cutters. Key Engineering Materials
407-408:292-297
[16] Lee YS (1998) Non-isoparametric tool path planning by machining strip
evaluation for 5-axis sculptured surface machining. Computer-Aided
Design 30 (7):559-570
[17] Fard MJB, Feng H-Y (2009) Effect of tool tilt angle on machining strip
width in five-axis flat-end milling of free-form surfaces. The International
Journal of Advanced Manufacturing Technology 44 (3-4):211-222
[18] Chiou C-J, Lee Y-S (2002) Swept surface determination for five-axis
numerical control machining. International Journal of Machine Tools and
Manufacture 42 (14):1497-1507
[19] Chiou JCJ, Lee YS (2005) Optimal tool orientation for five-axis tool-end
machining by swept envelope approach. Journal of manufacturing science
and engineering 127 (4):810-818
[20] Zhu LM, Zhang XM, Zheng G, Ding H (2009) Analytical expression of
the swept surface of a rotary cutter using the envelope theory of sphere
congruence. Journal of manufacturing science and engineering 131
(4):0410171-0410177
[21] Lin Z, Fu J, Shen H, Gan W (2014) A generic uniform scallop tool path
generation method for five-axis machining of freeform surface.
Computer-Aided Design 56:120-132
[22] Xu J, Zhang S, Tan J, Liu X (2012) Non-redundant tool trajectory
generation for surface finish machining based on geodesic curvature
matching. The International Journal of Advanced Manufacturing
Technology 62 (9-12):1169-1178
[23] Zhu LM, Zhang XM, Ding H, Xiong YL (2010) Geometry of signed
point-to-surface distance function and its application to surface
approximation. Journal of computing and information science in
engineering 10 (4):0410031-04100310
[1] Mullins S, Jensen C, Anderson D (1993) Scallop elimination based on
precise 5-axis tool placement, orientation, and step-over calculations.
ASME Adv Des Autom 65:535-544.
[2] Jensen C, Anderson D (1993) Accurate tool placement and orientation for
finish surface machining. Journal of Design and Manufacturing
59:127-127
[3] Rao N, Ismail F, Bedi S (1997) Tool path planning for five-axis
machining using the principal axis method. International Journal of
Machine Tools and Manufacture 37 (7):1025-1040
[4] Bedi S, Gravelle S, Chen Y (1997) Principal curvature alignment
technique for machining complex surfaces. Journal of manufacturing
science and engineering 119 (4B):756-765
[5] Rao N, Bedi S, Buchal R (1996) Implementation of the principal-axis
method for machining of complex surfaces. The International Journal of
Advanced Manufacturing Technology 11 (4):249-257
[6] Wang X, Wu X, Li Y (1992) Curvature catering—a new concept for
machining sculptured surfaces. Journal of Xi’an Jiaotong University 26
(5):51-58
[7] Gong H, Cao LX, Liu J (2008) Second order approximation of tool
envelope surface for 5-axis machining with single point contact.
Computer-Aided Design 40 (5):604-615
[8] Zhu LM, Ding H, Xiong YL (2010) Third-order point contact approach
for five-axis sculptured surface machining using non-ball-end tools (I):
Third-order approximation of tool envelope surface. SCIENCE CHINA
Technological Sciences 53 (7):1904-1912
[9] Zhu LM, Ding H, Xiong YL (2010) Third-order point contact approach
for five-axis sculptured surface machining using non-ball-end tools (II):
Tool positioning strategy. SCIENCE CHINA Technological Sciences 53
(8):2190-2197
[10] Warkentin A, Ismail F, Bedi S (2000) Multi-point tool positioning
strategy for 5-axis mashining of sculptured surfaces. Computer Aided
Geometric Design 17 (1):83-100
[11] Warkentin A, Ismail F, Bedi S (2000) Comparison between multi-point
and other 5-axis tool positioning strategies. International Journal of
Machine Tools and Manufacture 40 (2):185-208
[12] Gray P, Bedi S, Ismail F (2003) Rolling ball method for 5-axis surface
machining. Computer-Aided Design 35 (4):347-357
[13] Gray PJ, Bedi S, Ismail F (2005) Arc-intersect method for 5-axis tool
positioning. Computer-Aided Design 37 (7):663-674
[14] Zhang H (1987) The developing trend of sculptured surface machining in
increasing the strip width and decrease the scallop height. Surface
Machining and Checking
[15] Wang D, Chen WY, Li T, Xu RF (2009) Five-Axis Flank Milling of
Sculptured Surface with Barrel Cutters. Key Engineering Materials
407-408:292-297
[16] Lee YS (1998) Non-isoparametric tool path planning by machining strip
evaluation for 5-axis sculptured surface machining. Computer-Aided
Design 30 (7):559-570
[17] Fard MJB, Feng H-Y (2009) Effect of tool tilt angle on machining strip
width in five-axis flat-end milling of free-form surfaces. The International
Journal of Advanced Manufacturing Technology 44 (3-4):211-222
[18] Chiou C-J, Lee Y-S (2002) Swept surface determination for five-axis
numerical control machining. International Journal of Machine Tools and
Manufacture 42 (14):1497-1507
[19] Chiou JCJ, Lee YS (2005) Optimal tool orientation for five-axis tool-end
machining by swept envelope approach. Journal of manufacturing science
and engineering 127 (4):810-818
[20] Zhu LM, Zhang XM, Zheng G, Ding H (2009) Analytical expression of
the swept surface of a rotary cutter using the envelope theory of sphere
congruence. Journal of manufacturing science and engineering 131
(4):0410171-0410177
[21] Lin Z, Fu J, Shen H, Gan W (2014) A generic uniform scallop tool path
generation method for five-axis machining of freeform surface.
Computer-Aided Design 56:120-132
[22] Xu J, Zhang S, Tan J, Liu X (2012) Non-redundant tool trajectory
generation for surface finish machining based on geodesic curvature
matching. The International Journal of Advanced Manufacturing
Technology 62 (9-12):1169-1178
[23] Zhu LM, Zhang XM, Ding H, Xiong YL (2010) Geometry of signed
point-to-surface distance function and its application to surface
approximation. Journal of computing and information science in
engineering 10 (4):0410031-04100310
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:68791", author = "YaoAn Lu and QingZhen Bi and BaoRui Du and ShuLin Chen and LiMin Zhu and Kai Huang", title = "Five-axis Strip Machining with Barrel Cutter Based On Tolerance Constraint for Sculptured Surfaces", abstract = "Taking the design tolerance into account, this paper
presents a novel efficient approach to generate iso-scallop tool path for
five-axis strip machining with a barrel cutter. The cutter location is
first determined on the scallop surface instead of the design surface,
and then the cutter is adjusted to locate the optimal tool position based
on the differential rotation of the tool axis and satisfies the design
tolerance simultaneously. The machining strip width and error are
calculated with the aid of the grazing curve of the cutter. Based on the
proposed tool positioning algorithm, the tool paths are generated by
keeping the scallop height formed by adjacent tool paths constant. An
example is conducted to confirm the validity of the proposed method.
", keywords = "Strip machining, barrel cutter, iso-scallop tool path, sculptured surfaces, differential motion.", volume = "8", number = "10", pages = "1772-6", }
