Grind-free tool path generation for five-axis surface machining

Pi, J.; Red, Edward; Jensen, Greg

doi:10.1016/s0951-5240(98)00033-0

Cited by 36 publications

(12 citation statements)

References 12 publications

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“…However, the proposed equation is no longer adequate for intricate surfaces, as both complete removal and local removals are not equivalently distributed in the entire contact area due to the complex geometry of the workpiece that is machined. According to the brief literature review above, it can be concluded that most of the previous research works concentrated on cutting path optimization, thereby making regular contact resulting in constant material removal [6][7][8][9]. Though the removal of material in the belt grinding process from the workpiece surface can be written as a function of several parameters, their influence and interaction have not been reported in the literature that will be covered and bridged in this research work.…”

Section: Introductionmentioning

confidence: 97%

Predictive Modelling and Analysis of Process Parameters on Material Removal Characteristics in Abrasive Belt Grinding Process

et al. 2017

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Abstract:The surface finishing and stock removal of complicated geometries is the principal objective for grinding with compliant abrasive tools. To understand and achieve optimum material removal in a tertiary finishing process such as Abrasive Belt Grinding, it is essential to look in more detail at the process parameters/variables that affect the stock removal rate. The process variables involved in a belt grinding process include the grit and abrasive type of grinding belt, belt speed, contact wheel hardness, serration, and grinding force. Changing these process variables will affect the performance of the process. The literature survey on belt grinding shows certain limited understanding of material removal on the process variables. Experimental trials were conducted based on the Taguchi Method to evaluate the influence of individual and interactive process variables. Analysis of variance (ANOVA) was employed to investigate the belt grinding characteristics on material removal. This research work describes a systematic approach to optimise process parameters to achieve the desired stock removal in a compliant Abrasive Belt Grinding process. Experimental study showed that the removed material from a surface due to the belt grinding process has a non-linear relationship with the process variables. In this paper, the Adaptive Neuro-Fuzzy Inference System (ANFIS) model is used to determine material removal. Compared with the experimental results, the model accurately predicts the stock removal. With further verification of the empirical model, a better understanding of the grinding parameters involved in material removal, particularly the influence of the individual process variables and their interaction, can be obtained.

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Section: Introductionmentioning

confidence: 97%

Predictive Modelling and Analysis of Process Parameters on Material Removal Characteristics in Abrasive Belt Grinding Process

et al. 2017

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“…The forward step is usually determined by the maximum chordal deviation (Pi, Red, and Jensen 1998). Chordal deviation is the distance between the line connecting 2 CC points and the actual curve on the free-form surface (Figure 2(d)).…”

Section: Generation Of Initial Semi-finishing and Finishing Tool Pathsmentioning

confidence: 99%

Tool path re-planning in free-form surface machining for compensation of process-related errors

Lasemi

Xue

2014

International Journal of Production Research

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Free-form surfaces are widely used in many applications in today's industry. This paper presents a new approach to identify and compensate process-related errors in machining of free-form surfaces. The process-related errors are identified online by a newly developed in-process inspection technique. In this technique, the surface is first machined through an intermediate semi-finishing process that is specifically designed to machine different geometric shapes on the surface with different process parameters. An inspection method is developed to identify the process-related errors in the selected regions on the semi-finished surface. The relationship between the machining/surface parameters and process-related error is then achieved using a neural network. This relationship is used to predict the process-related errors in the finishing process. The process-related errors, together with the machine tool geometric errors identified using a method developed in our previous work, are compensated in the finishing tool paths through tool path re-planning. Experiment has been conducted to machine a part with a free-form surface to show the improvements in the machining accuracy.

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“…The geometry of surface curve S(u 0 , v) at the vicinity of C i can be considered as a circular curve, as shown in figure 4(a), and the radius of the circle is the radius of curvature n at C i in the direction of cutter direction. Then the step-forward size L i is given by (Pi et al 1998): L i is then converted to the parameter increment Áv i , so that we can get the next CC point S(u 0 , v i þ Áv i ). As shown in figure 4(b), the conversion is determined by solving the following equation:…”

Section: Determining the Cutter Contact (Cc) Pointsmentioning

confidence: 99%

“…On the other hand, much work focuses on the detection and avoidance of gouging and collision. Gouging is the main problem in finishing sculptured surfaces (Lee 1997, Pi et al 1998, Rao and Sarma 2000, which occurs when portions of the cutter's bottom extends below the part surface. Collision is regarded as the global gouging in which the cylindrical portion of the cutter interferes with the part surface or the machine tool.…”

Section: Introductionmentioning

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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Grind-free tool path generation for five-axis surface machining

Cited by 36 publications

References 12 publications

Predictive Modelling and Analysis of Process Parameters on Material Removal Characteristics in Abrasive Belt Grinding Process

Predictive Modelling and Analysis of Process Parameters on Material Removal Characteristics in Abrasive Belt Grinding Process

Tool path re-planning in free-form surface machining for compensation of process-related errors

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

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