Tool Path Planning for 5-Axis Flank Milling Based on Dynamic Programming Techniques
ABSTRACT This paper proposes a novel computation method for tool path planning in 5-axis flank milling of ruled surfaces. This method
converts the path planning (a geometry problem) into a curve matching task (a mathematical programming problem). Discrete
dynamic programming techniques are applied to obtain the optimal matching with machining error as the objective function.
Each matching line corresponds to a cutter location and the tool orientation at the location. An approximating method based
on z-buffer is developed for a quick estimation of the error. A set of parameters is allowed to vary in the optimization,
thus generating the optimal tool paths in different conditions. They reveal useful insights into design of the tool motion
pattern with respect to the surface geometry. The simulation result of machining different surfaces validates the proposed
method. This work provides an effective systematic approach to precise error control in 5-axis flank milling.
- SourceAvailable from: Sanjeev Bedi[show abstract] [hide abstract]
ABSTRACT: This paper presents a positioning strategy for flank milling ruled surfaces. It is a modification of a positioning method developed by Bedi et al. [Comput Aided Des 35 (2003) 293]. A cylindrical cutting tool is initially positioned tangential to the two boundary curves on a ruled surface. Optimization is used to move these tangential points to different curves on the ruled surface to reduce the error. A second optimization step is used to additionally make the tool tangent to a rule line, further reducing the error and resulting in a tool position, where the tool is positioned tangential to two guiding rails and one rule line. The resulting surface has 88% less under cutting than the method of Bedi et al.Computer-Aided Design. 07/2003;
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ABSTRACT: In theory, the five-axis numerical control (NC) machining of sculptured surfaces can be classified into facing milling and cylindrical milling (or side milling). In general, the first one, using flat-end cutter, is suitable for the machining of large sculptured surfaces, e.g. the blade of hydraulic turbine, whose binding relations with drive surface (DS) and check surface (CS) are simple, and the second one, using cylindrical cutter, has wide applications for the milling of small and middle dimensional surfaces whose binding relations with DS and CS are more complex, such as the milling of integral turbine wheels. In practice, the second one suffers more difficulties than the first one, which are mostly related to gouge avoidance, interference avoidance and tool strength. This paper, on the basis of the theories of differential geometry and analytical geometry, describes research on algorithms for the toolpath generation of five-axis cylindrical milling of sculptured surfaces with cylindrical cutter. The approach includes (a) single point offset (SPO) algorithm, and (b) double point offset (DPO) algorithm for the cutter location data (CLDATA) calculation of five-axis cylindrical milling.Computer-Aided Design. 01/1995;
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ABSTRACT: This paper deals with assessment and correction of tool path in 5-axis machining. The tool trajectory is described using two curves; each one corresponding to the trajectory of two particular points of the tool axis. The assessment of the tool path is performed via the calculation of the envelope surface, which is calculated using a kinematics approach. The geometrical deviations between the envelope surface and the nominal surface are calculated. When necessary, the tool path is corrected, so that the envelope surface fits the ideal surface as much as possible. This correction is carried out by the deformation of both curves that are representative of the tool trajectory. We choose to illustrate our purpose through flank milling of sculptured surfaces.Computer-Aided Design. 01/2003;