Five-axis Tool Path Generation for Sculptured Surface Machining using Rational Bézier Motions of a Flat-end Cutter

Zhang, W.; Zhang, Y. F.; Ge, Q. J.

doi:10.1080/16864360.2004.10738265

Cited by 4 publications

(3 citation statements)

References 30 publications

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“…The distance between this point and the designed surface is taken as the scallop height at the CC point. For details of resolving equation (21), identifying the right intersection point between the two effective cutting shapes, and calculating the distance from the intersection point to the designed surface, readers can refer to Zhang (2004).…”

Section: Scallop Height and Effective Cutting Shapementioning

confidence: 99%

Interference-free tool path generation for 5-axis sculptured surface machining using rational Bézier motions of a flat-end cutter

Zhang

2005

International Journal of Production Research

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This paper presents a new approach that uses rational Be´zier motions to generate 5-axis tool path for sculptured surface machining (finish cut) with a flat-end cutter. By using dual quaternion to represent a spatial displacement, the representation of kinematic motions for the cutter bottom circle of the flat-end cutter is formulated. Based on that, a new approach for tool path generation using rational Be´zier cutter motions is described, in which key issues such as interference avoidance and surface accuracy requirement are addressed. First, a set of cutter contact points on an iso-parametric curve of the designed surface is obtained based on a given fitting tolerance. The associated cutter locations (CLs) are then obtained by finding the suitable cutter orientations that avoid any gouging. The conversion from the CLs to dual quaternion representation is carried out and the rational Be´zier dual quaternion curve for cutter motion is generated. The entire tool path is therefore established based on the cutter undergoing the rational Be´zier motion. Next, the whole tool path is checked to find (1) if there is any interference between the cutter and the designed surface, and (2) whether the deviation between the surface generated by the cutter motion and the designed surface is larger than the given tolerance. The problematic CLs, which cause either gouging or accuracy problem, are then modified. The process of tool path checking ! CLs modification ! tool path regeneration continues until the whole tool path is interference-free and satisfies the accuracy requirement. Furthermore, a more accurate representation of the effective cutting shape is proposed, which is used to evaluate the scallop height between adjacent tool paths. A method for constructing the adjacent tool path has been developed by considering the allowable scallop height. Finally, computer implementation and an illustrative example are presented to demonstrate the efficacy of the approach.

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Section: Scallop Height and Effective Cutting Shapementioning

confidence: 99%

Interference-free tool path generation for 5-axis sculptured surface machining using rational Bézier motions of a flat-end cutter

Zhang

2005

International Journal of Production Research

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“…Ge and Sirchia [35] studied the problem of computer aided geometric design of two-parameter freeform motions by combining CAGD methods with the kinematics of two-parameter motion. One of the motivations for studying two-parameter freeform motions is to develop a kinematics based approach to geometric shape design and 5-axis NC tool path planning (Ge [36], Zhang et al [37]).…”

Section: Introductionmentioning

confidence: 99%

Automatic Fairing of Two-Parameter Rational B-Spline Motion

Purwar

Chi

2007

Journal of Mechanical Design

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This paper deals with the problem of automatic fairing (or fine-tuning) of two-parameter rational B-spline spherical and spatial motions. The results presented in this paper extend the previous results on fine-tuning of one-parameter rational B-spline motions. A dual quaternion representation of spatial displacements is employed and the problem of fairing two-parameter motions is studied as a surface fairing problem in the space of dual quaternions. By combining surface fairing techniques from the field of computer aided geometric design with the computer aided synthesis of freeform rational motions, smoother (C3 continuous) two-parameter rational B-spline motions are generated. Several examples are presented to illustrate the effectiveness of the proposed method. Techniques for motion smoothing have important applications in the Cartesian motion planning, camera motion synthesis, and spatial navigation in virtual reality systems. In particular, smoother two-parameter freeform motions have applications in the development of a kinematic based approach to geometric shape design and in five-axis NC tool path planning.

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“…Monies et al (2004) defined global gouging based on the collision between the cutter body and part surfaces, and determined a complete tool trajectory free from the global gouging, while Zhang et al (2005) attempted to remove local gouging by using concentric circles generated by filletend mills. Chen et al (2005) divided the machining surface into convex and non-convex regions according to the occurrence of tool collision, which avoided local and the global gouging.…”

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confidence: 99%

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

Heo

Kim

et al. 2008

International Journal of Computer Integrated Manufacturing

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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.

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Five-axis Tool Path Generation for Sculptured Surface Machining using Rational Bézier Motions of a Flat-end Cutter

Cited by 4 publications

References 30 publications

Interference-free tool path generation for 5-axis sculptured surface machining using rational Bézier motions of a flat-end cutter

Interference-free tool path generation for 5-axis sculptured surface machining using rational Bézier motions of a flat-end cutter

Automatic Fairing of Two-Parameter Rational B-Spline Motion

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

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