An analytical method for obtaining cutter workpiece engagement during a semi-finish in five-axis milling

Kiswanto, Gandjar; Hendriko, Hendriko; Duc, Emmanuel

doi:10.1016/j.cad.2014.05.003

Cited by 55 publications

(42 citation statements)

References 20 publications

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“…λ C is the toroidal angle of the LE point that was calculated using the grazing method discussed in [21]. For a toroidal cutter, l n was the length of the CWE on the cylindrical side.…”

Section: Curved Surfacementioning

confidence: 99%

“…When the workpiece surface was a free-form surface, the authors of that study used a discretization method to represent the workpiece surface. Kiswanto et al [21] proposed an analytical method called the Analytical Boundary Simulation to define the cutter-workpiece engagement (CWE) in five-axis milling. The proposed method was proven accurate and faster than Z-mapping method; however, the method was only applicable to semi-finishing processes using a workpiece with a straight staircase surface profile.…”

Section: Introductionmentioning

confidence: 99%

“…After obtaining these two points, the length of each cut at every engagement angle can be calculated. The LE point was calculated using the grazing method described in [21] and will not be discussed in this paper. A flow chart describing the steps used to obtain the LE point and the UE point are presented in Fig.…”

Section: Introductionmentioning

confidence: 99%

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A hybrid analytical- and discrete-based methodology for determining cutter-workpiece engagement in five-axis milling

Kiswanto

Hendriko

Duc

2015

Int J Adv Manuf Technol

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This paper presents a new method to determine the cutter-workpiece engagement (CWE) for a toroidal cutter during free-form surface machining in five-axis milling. A hybrid method, which is a combination of a discrete model and an analytical approach, was developed. Although the workpiece surface was discretized by a number of normal vectors, there was no calculation to determine the intersection between the normal vector and the cutting tool. The normal vectors were used to define the workpiece surface mathematically; next, the engagement point was calculated using a combination of the workpiece surface equation, the parametric equation of the cutting tool, and the tool orientation data. Three model parts with different surface profiles were tested to verify the validity of the proposed method; the results indicated that the method was accurate. The method also eliminated the need for a large number of discrete vectors to define the workpiece surface. A comparison showed that the proposed method was computationally more efficient. The CWE model was subsequently applied to support the cutting force prediction model. A validation test demonstrated that in terms of trends and amplitudes, the predicted cutting forces exhibit good agreement with the cutting force generated experimentally.

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“…λ C is the toroidal angle of the LE point that was calculated using the grazing method discussed in [21]. For a toroidal cutter, l n was the length of the CWE on the cylindrical side.…”

Section: Curved Surfacementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

A hybrid analytical- and discrete-based methodology for determining cutter-workpiece engagement in five-axis milling

Kiswanto

Hendriko

Duc

2015

Int J Adv Manuf Technol

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“…Sun and Guo used the Newton iteration method to calculate the boundary of CWE between the cutter and workpiece [14]. Kiswanto et al established an analytical semifinished tangent region model based on surface profile [15]. Wei et al discretized sculptured surface into a series of microelement planes.…”

Section: Introductionmentioning

confidence: 99%

A Prediction Model of Cutting Force about Ball End Milling for Sculptured Surface

Mou

Zhu

et al. 2020

Mathematical Problems in Engineering

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Cutting force prediction is very important to optimize machining parameters and monitor machining state. In order to predict cutting force of sculptured surface machining with ball end mill accurately, tool posture, cutting edge, contact state between cutter, and workpiece are studied. Firstly, an instantaneous motion model of ball end mill for sculptured surface is established. The instantaneous milling coordinate system and instantaneous tool coordinate system are defined to describe the position and orientation of tool, and the transformation matrix between coordinate systems is derived. Secondly, by solving three boundaries around engagement of cutter and workpiece, a cutter-workpiece engagement model related to tool posture, milling parameters, and tool path is established. It has good adaptability to the variable tool axis relative to the machining surface. Finally, an algorithm of thickness about an instantaneous undeformed chip is researched, and a prediction model of cutting force is realized with microelement cutting theory. Also, the model is suitable for sculptured surface machining with arbitrary tool posture and feed direction. The accuracy of the proposed prediction model was verified by a series of experiments.

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“…The orientation of cutting tool was determined by calculating the cutting edge rotation angles about the X-axis ( ) and the Y-axis ( ). By refering to Figure 1a, the orientation angle of cutting tool were calculated as follows, (5) Then the operator to map the coordinate system from the TCS to the WCS involving the tool rotation about the x-axis, the y-axis and a translation at T was expressed as follows, (6) …”

Section: Identifying the Tool Mapping Operator And The Tool Orientatimentioning

confidence: 99%

Effect of helical angle on path scallop calculation of flat-end cutter in multi axis milling

Hendriko

2017

AIP Conference Proceedings

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Abstract. This paper presents an analytical method to calculate path scallop height of flat-end cutter during free-form surface machining. In this study the effect of helical angle of cutting edge was taken into consideration in the calculation. The scallop height was determined from the coordinate of the path intersection point. Path intersection point is an intersection between the cutting tool of the current tooth path and the previous tooth path. One model part with free-form surface was tested to verify the applicability of the proposed method. The scallop height obtained using the tool with helical angle and the one without helical angle were compared. The result showed that the helical angle tend to decrease the scallop height. The verification test to check the accuracy of the proposed method was performed. The result proved that the method was accurate.

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An analytical method for obtaining cutter workpiece engagement during a semi-finish in five-axis milling

Cited by 55 publications

References 20 publications

A hybrid analytical- and discrete-based methodology for determining cutter-workpiece engagement in five-axis milling

A hybrid analytical- and discrete-based methodology for determining cutter-workpiece engagement in five-axis milling

A Prediction Model of Cutting Force about Ball End Milling for Sculptured Surface

Effect of helical angle on path scallop calculation of flat-end cutter in multi axis milling

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