Comparison of 5-Axis and 3-Axis Finish Machining of Hydroforming Die Inserts

Gray, Paul J.; Bedi, Sanjeev; Ismail, F.; Rao, N.; Morphy, Gary

doi:10.1007/s001700170139

Cited by 23 publications

(10 citation statements)

References 7 publications

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“…When finish milling using a three-axis or five-axis NC machine, the tool axis with respect to the workpiece surface is crucial in achieving optimum workpiece surface roughness and accuracy [24]. A minimum tool or workpiece inclination angle, known as Sturz method or inclined method [25] is defined such that cutter axis or workpiece material is tilted at a constant angle with respect to a surface normal. Ball nose cutter is generally used for finish milling due to the fact that the cutter readily adapts well to machining free form surfaces.…”

Section: Effects Of Inclined Millingmentioning

confidence: 99%

A study of the effects of cutter path strategies and orientations in milling

Toh

2004

Journal of Materials Processing Technology

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Section: Effects Of Inclined Millingmentioning

confidence: 99%

A study of the effects of cutter path strategies and orientations in milling

Toh

2004

Journal of Materials Processing Technology

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“…Sometimes this issue may cause the machined part to be discarded as useless. Therefore, although five-axis machining has been shown to reduce machining times over three-axis, these problems make it difficult to gain wider acceptance in industry (Gray et al, 2001). To avoid such difficulties, the reverse movements and abrupt changes of moving axes must be avoided when planning tool paths.…”

Section: Introductionmentioning

confidence: 99%

Four-axis tool orientation smoothing for spiral machining of blades based on step length

Shan

Chen

Duan

et al. 2014

Proceedings of the 2014 International Conference on Innovative Design and Manufacturing (ICIDM)

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A regular four-axis computer numerical control (CNC) machine is always used to produce blades by spiral machining method in many medium-sized and small industries. Generally, the four-axis CNC machine has the characteristic of low precision, which often leads to some obvious tiny tool marks like overcut on the blade surface. To overcome this problem, a tool orientation smoothing method is developed and implemented. Key issues are focused on tool orientation smoothing in four-axis spiral machining of blades, and concrete contributions are twofold. First, according to the primary curvature radii and parameter characteristics, the parameter range of blade surface is subdivided into four subregions. Second, tool orientation smoothing method for four subregions of blade surface is addressed in detail based on the step length of cutter contact (CC) points in fouraxis spiral machining. A test shows that tool marks that easily occur in four-axis machining can be effectively reduced by using the proposed method.

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“…The faster machining times and superior surface finishes characteristic of 5-axis machining are achieved by using flat and rounded endmills instead of a ball endmill [1][2][3][4][5]. In addition, the complex multiple setups necessary in conventional 3-axis machining can be done more efficiently with a single setup [6].…”

Section: Introductionmentioning

confidence: 99%

CL surface deformation approach for a 5-axis tool path generation

Kim

Lee

Kim

et al. 2005

Int J Adv Manuf Technol

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In this paper, the 5-axis tool path that has been generated on the cutter contact (CC) surface is generated on the cutter location (CL) surface, and the CL surface deformation approach that inversely deforms the 3-axis tool path generated on the deformed CL surface to a 5-axis tool path is introduced. The CL point computation and interference check based on the CL surface is faster and more robust than that based on the CC surface. The proposed CL surface deformation approach can be used if the orientation of the cutter is predefined. By the CL surface deformation approach, the 5-axis tool path generation time can be reduced to that of a 3-axis, since the complexity of a CL surface deformation is linear and because the 3-axis tool path generation and gouge removal algorithms are used at the deformed CL surface.

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Comparison of 5-Axis and 3-Axis Finish Machining of Hydroforming Die Inserts

Cited by 23 publications

References 7 publications

A study of the effects of cutter path strategies and orientations in milling

A study of the effects of cutter path strategies and orientations in milling

Four-axis tool orientation smoothing for spiral machining of blades based on step length

CL surface deformation approach for a 5-axis tool path generation

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