Efficient rough-cut plan for machining an impeller with a 5-axis NC machine

Abstract

2008) Efficient rough-cut plan for machining an impeller with a 5-axis NC machine, International Journal of Computer Integrated Manufacturing, 21:8,[971][972][973][974][975][976][977][978][979][980][981][982][983] This study presents an efficient, rough-cut path plan for the 5-axis, numerically controlled (NC) machining of an impeller. The hub and blade surfaces of the impeller are customarily machined by a 5-axis NC machine. Much of the machining time of the impeller is, however, consumed in the rough cutting where unnecessary stock materials are removed. Simultaneous, 5-axis, rough machining requires a considerably longer time than 3-axis machining because all the five axes have to be controlled at the same time at almost all cutter location (CL) points. Based on the characteristic curves of a blank and a finished impeller, a rough machining area can be partitioned into several unit machining regions (UMRs) by using the characteristic curves of an impeller and their projection graphs. Then, an UMR is machined by means of the simultaneous, 3-axis control of a 5-axis machine instead of simultaneous, 5-axis control. In each UMR, the rotating and tilting axes of a machine bed are fixed in advance to perform 3-axis machining. Finally, rough-cut CL data is generated based on the 3-axis machining plan at each UMR while avoiding the collision between the tool and impeller blades. An illustrative example is shown for a prototype impeller, and the final tool paths generated by the proposed method are verified by using the cutting simulation function of Vericut 1 . Experimental results show that the proposed rough-cut plan has significantly reduced the machining time when compared to the conventional, 5-axis-control-based, rough machining.

CBIMS: Case-based impeller machining strategy support system

“…However, their study did not account for the efficiency of their rough-cut plan in terms of machining time. In this sense, Heo et al [8] proposed a machining region partitioning method considering tool diameters and tool approach vectors concurrently so as to decrease the impeller machining time, producing partitioned unit machining regions with tool approach vectors that are free from tool collision with blade surfaces.…”

Particle swarm optimisation (PSO)-based tool path planning for 5-axis flank milling accelerated by graphics processing unit (GPU)

“…This machining operation provides higher productivity and better shaping capability over traditional 3-axis machining (Heo et al 2008). It is commonly used in the manufacture of aerospace, automobile, energy, and mold parts.…”

Emergent Structure Detection for Multi-Axis Machining

“…Umehara et al make the same use of discrete orientations in 5-axis impeller milling [7]. Heo et al derive machining orientations by projecting the ruled surface of impeller blades into visibility regions [3]. Further, Heo et al show that machining time is actually reduced by using a 3+2 milling milling strategy (rather than full 5-axis control) in impeller blade machining.…”

“…Previous researchers have suggested that rough machining is the most important process affecting machining time and product accuracy in multi-axis machining [1,2], while others report that rough machining accounts for 50% to 90% of machining time [3,4].…”

“…In this study, we prefer to analyze the complement of tool space and machinable space because they represent the transient stock condition that we wish to find. While we omit the algebra here, we can rigorously show that tool space is the cumulative union of visibility polygon offsets by the projected tool radius: (3) and that machinable space is the cumulative intersection of tool space reverse offsets by the projected tool radius:…”