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.
Abstract: Optimization of cutting parameters important in precision machining in regards to efficiency and surface integrity of the machined part. Usually productivity and precision in machining is limited by the forces emanating from the cutting process. Due to the inherent varying nature of the workpiece in terms of geometry and material composition, the peak cutting forces vary from point to point during machining process. In order to increase productivity without compromising on machining accuracy, it is important to control these cutting forces. In this paper a fuzzy logic control algorithm is developed that can be applied in the control of peak cutting forces in milling of spherical surfaces using ball end mills. The controller can adaptively vary the feedrate to maintain allowable cutting force on the tool. This control algorithm is implemented in a computer numerical control (CNC) machine. It has been demonstrated that the controller can provide stable machining and improve the performance of the CNC milling process by varying feedrate.