A novel minimum-time feedrate schedule method for five-axis sculpture surface machining with kinematic and geometric constraints

Li, Hai; Wang, Wei; Li, Qingzhao; Huang, Pu

doi:10.1177/0954405418780167

Cited by 4 publications

(4 citation statements)

References 30 publications

(40 reference statements)

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“…There has been a number of studies that focused on the kinematic modeling and the creation of postprocessors for the 5-axis CNC machines. 3–25 The kinematic modeling and the postprocessor creation for specific 5-axis CNC machines with the non-orthogonal rotary axes were investigated. 3–8 The methods for creating CNC postprocessors for the individual 5-axis CNC machines with the orthogonal rotary axes were proposed by Refs.…”

Section: Introductionmentioning

confidence: 99%

“…Makhanov and Munlin 11 formulated the kinematics model of the 5-axis CNC machine MAHO 600e, with the introduced algorithms to correct the trajectories of the tool tip of a 5-axis milling machine by adjusting the rotation angles in such a way that the kinematics error is reduced. The kinematic modeling of the 5-axis CNC machines was also studied in Refs 16–18 for the purpose of the feed rate scheduling and geometric tolerance analysis. There have been efforts and studies to formulate the kinematics model of a general 5-axis CNC machine, with different machine configurations and working mechanism.…”

Section: Introductionmentioning

confidence: 99%

“…My et al 25 proposed a general approach for the kinematic modeling of the two rotary axes of the 5-axis CNC machines. Although there have been investigations, as shown in the above-mentioned attempts, 3–25 that aims to obtain solutions for a generalized kinematic modeling of 5-axis CNC machines, a little attention has been paid to formulation of the kinematic model in a simplified and explicit manner that make it possible to create CNC postprocessors intuitively, without the required strong backgrounds and skills for engineers or CNC operators in mathematical modeling and kinematics of machines, especially mathematical modeling of multibody systems, with the advanced knowledges of kinematic modeling and complex mathematic transformations.…”

Section: Introductionmentioning

confidence: 99%

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A framework for practically effective creation of postprocessors for 5-axis CNC machines with all possible configurations and working mechanisms

Lê

Hoang

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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The 5-axis CNC (Computer Numerical Control) machining plays an important role in manufacturing, especially in making parts of complex shapes such as turbine or propeller blades. However, there are always challenges of generating 5-axis CNC machining programs when working with different 5-axis CNC machines of various structures; and 5-axis CNC programs must be automatically generated by CNC postprocessors which calculate the inverse kinematics and convert the Cutter Location data to the CNC programs that are used for operating 5-axis CNC machines. Since the family of 5-axis CNC machines has a wide spectrum of machine configurations, with hundreds of mechanisms of 5 degrees of freedom, it is therefore practically challenging for engineers and CNC machine operators to create CNC postprocessors for specific 5-axis CNC machines. It is more challenging to create CNC postprocessors if engineers or CNC operators do not have strong backgrounds and professional skills in mathematical modeling and kinematics of machines. This paper presents a universal and intuitive framework and practical guidance to create CNC postprocessors for all 5-axis CNC machines, with the focus on a novel mathematical formulation of inverse kinematics of three main groups of 5-axis CNC machines. The case studies of creating CNC postprocessors with the commercially available 5-axis CNC machines were successfully demonstrated, in which the simulation scenarios and experiments were implemented to verify the created CNC postprocessors. The proposed frameworks and guides for generating CNC postprocessors can be conveniently and effectively applied in industrial practices, without the required strong backgrounds and skills for engineers or CNC operators in mathematical modeling and kinematics of machines, especially mathematical modeling of multibody systems.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

A framework for practically effective creation of postprocessors for 5-axis CNC machines with all possible configurations and working mechanisms

Lê

Hoang

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…4 One can schedule constant feedrate with initial launching and final braking for routine linear or circular toolpaths, while for free-form spline toolpaths, it is no longer suitable because the variable geometry within one spline toolpath requires different axial drive capabilities. 5 If a constant speed is utilized, the feedrate must be scheduled as a most conservative value so as to compromise to the most dangerous area on the spline. 6 Therefore, scheduling the feedrate adaptively becomes so significant that it has been researched in a lot of literatures.…”

Section: Introductionmentioning

confidence: 99%

Look-ahead-window-based interval adaptive feedrate scheduling for long five-axis spline toolpaths under axial drive constraints

Song

Zhong

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Scheduling of the five-axis spline toolpath feedrate is of great significance for high-quality and high-efficiency machining using five-axis machine tools. Due to the fact that there exists nonlinear relationship between the Cartesian space of the cutting tool and the joint space of the five feed axes, it is a challenging task to schedule the five-axis feedrate under axial drive constraints. Most existing methods are researched for routine short spline toolpaths, however, the five-axis feedrate scheduling method expressed for long spline toolpaths is limited. This article proposes an interval adaptive feedrate scheduling method based on a dynamic moving look-ahead window, so as to generate smooth feedrate for long five-axis toolpath in a piecewise manner without using the integral toolpath geometry. First, the length of the look-ahead window which equals to that of the toolpath interval is determined in case of abrupt braking at the end of the toolpath. Then, the interval permissible tangential feed parameters in terms of the velocity, acceleration, and jerk are determined according to the axial drive constraints at each toolpath interval. At the same time, the end velocity of the current interval is obtained through looking ahead the next interval. Using the start and end velocities and the permissible feed parameters of each interval, the five-axis motion feedrate is scheduled via an interval adaptive manner. Thus, the feedrate scheduling task for long five-axis toolpath is partitioned into a series of extremely short toolpaths, which realizes the efficient scheduling of long spline toolpath feedrate. Experimental results on two representative five-axis spline toolpaths demonstrate the feasibility of the proposed approach, especially for long toolpaths.

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Investigation of conventional and ANN-based feed rate scheduling methods in trochoidal milling with cutting force and acceleration constraints

Jacsó

Szalay

Sikarwar

et al. 2023

Int J Adv Manuf Technol

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In CNC milling, the feed rate scheduling is a frequently used method to increase machining quality and efficiency. Among the benefits of feed rate scheduling, this paper focuses on controlling the tool load and optimizing the machining time. Although the advantages of feed rate scheduling are undeniable, some areas remain still to be addressed. In order to control the tool load, geometric methods are often used, which are based on keeping a specific parameter, such as chip thickness or material removal rate (MRR) constant. However, a high level of tool load control can only be provided if cutting force models or experimental-based techniques are used. Besides traditional methods, this paper presents an artificial neural network (ANN)-based feed rate scheduling method to keep the tool load constant, using data gained by preliminary cutting experiments. A case study demonstrates that a significantly higher level of tool load control can be achieved with this method as compared to the geometric models. Besides controlling the tool load, the present feed rate scheduling method also addresses the consideration of acceleration limits which is of great importance for practical uses. The application of feed rate scheduling in trochoidal milling is also discussed in detail in this paper. This area has not received enough attention, as due to the limited fluctuation of cutter engagement, the tool load was considered as well-controlled. However, experiments have shown that in the case of trochoidal milling, the introduction of feed rate scheduling can still further increase the machining efficiency. Using the developed ANN-based feed rate scheduling method, significant progress could be made as compared to conventional technologies in controlling the cutting force and optimizing the machining time. In the present case study, a reduction of 50% in machining time was achievable by adjusting the feed rate without increasing the peak value of cutting force.

show abstract

A novel minimum-time feedrate schedule method for five-axis sculpture surface machining with kinematic and geometric constraints

Cited by 4 publications

References 30 publications

A framework for practically effective creation of postprocessors for 5-axis CNC machines with all possible configurations and working mechanisms

A framework for practically effective creation of postprocessors for 5-axis CNC machines with all possible configurations and working mechanisms

Look-ahead-window-based interval adaptive feedrate scheduling for long five-axis spline toolpaths under axial drive constraints

Investigation of conventional and ANN-based feed rate scheduling methods in trochoidal milling with cutting force and acceleration constraints

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