Optimization of 5-axis high-speed machining using a surface based approach

Lavernhe, Sylvain; Tournier, Christophe; Lartigue, Claire

doi:10.1016/j.cad.2008.08.006

Cited by 66 publications

(35 citation statements)

References 24 publications

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“…The smoothness of the motion of the milling tool is equally important for machining efficiency [11,15,29]. Lavernhe et.…”

Section: Previous Work and Contributionsmentioning

confidence: 99%

“…Lavernhe et. al [11] optimize the tool axis orientation to satisfy certain kinematic constraints which results in a higher speed of the tool and consequently in shorter machining time. Pechard et al [15] minimize the distance between the designed and machined surfaces while preserving the smoothness of the tool's trajectory.…”

Section: Previous Work and Contributionsmentioning

confidence: 99%

“…If the objective is to perform a high-speed milling as in [11], (11) could be eventually modified to comfort the proper velocity constraints. Since our primary objective was the approximation quality in terms of the minimum one-sided distance between Φ and Ω, we did not experiment with highspeed performance.…”

Section: Additional Constraintsmentioning

confidence: 99%

See 2 more Smart Citations

Towards efficient 5-axis flank CNC machining of free-form surfaces via fitting envelopes of surfaces of revolution

Bartoň

Plakhotnik³

et al. 2016

Computer-Aided Design

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We introduce a new method that approximates free-form surfaces by envelopes of one-parameter motions of surfaces of revolution. In the context of 5-axis computer numerically controlled (CNC) machining, we propose a flank machining methodology which is a preferable scallop-free scenario when the milling tool and the machined free-form surface meet tangentially along a smooth curve. We seek both an optimal shape of the milling tool as well as its optimal path in 3D space and propose an optimization based framework where these entities are the unknowns. We propose two initialization strategies where the first one requires a user's intervention only by setting the initial position of the milling tool while the second one enables to prescribe a preferable tool-path. We present several examples showing that the proposed method recovers exact envelopes, including semi-envelopes and incomplete data, and for general free-form objects it detects envelope sub-patches.

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“…The smoothness of the motion of the milling tool is equally important for machining efficiency [11,15,29]. Lavernhe et.…”

Section: Previous Work and Contributionsmentioning

confidence: 99%

Section: Previous Work and Contributionsmentioning

confidence: 99%

See 1 more Smart Citation

Towards efficient 5-axis flank CNC machining of free-form surfaces via fitting envelopes of surfaces of revolution

Bartoň

Plakhotnik³

et al. 2016

Computer-Aided Design

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show abstract

“…Over the years, much research has been aimed at reducing machining time by manipulating cutting parameters as a part of process planning (Bouzid, 2005;Lavernhe, Tournier, & Lartigue, 2008;Palanisamy, Rajendran, & Shanmugasundaram, 2007). A good surface finish with low machining time can be obtained through the proper selection of machining parameters (Bharathi Raja & Baskar, 2012).…”

Section: Cutting Tools and Machining Operationsmentioning

confidence: 99%

End mill tools integration in CNC machining for rapid manufacturing processes: simulation studies

Zahid

Case

Watts

2015

Production & Manufacturing Research

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Computer numerical controlled (CNC) machining has been recognized as a manufacturing process that is capable of producing metal parts with high precision and reliable quality, whereas many additive manufacturing methods are less capable in these respects. The introduction of a new layer-removal methodology that utilizes an indexing device to clamp the workpiece can be used to extend CNC applications into the realm of rapid manufacturing (CNC-RM) processes. This study aims to improve the implementation of CNC machining for RM by formulating a distinct approach to integrate end mill tools during finishing processes. A main objective is to enhance process efficiency by minimizing the staircasing effect of layer removal so as to improve the quality of machined parts. In order to achieve this, different types of end mill tools are introduced to cater for specific part surfaces during finishing operations. Virtual machining simulations are executed to verify the method and the implications. The findings indicate the advantages of the approach in terms of cutting time and excess volume left on the parts. It is shown that using different tools for finishing operations will improve the capabilities of CNC machining for rapid manufacturing applications.

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“…The prediction of the velocity profile generated by the CNC was used in [17,18] to improve the machining time by changing the orientation of the tool. Although the complete motion planning is the best way to see where the feedrate is decreasing, it is time consuming and not necessary for the purpose of trajectory smoothing.…”

mentioning

confidence: 99%

5-Axis tool path smoothing based on drive constraints

Beudaert

Pechard²,

Tournier

2011

International Journal of Machine Tools and Manufacture

Self Cite

115

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In high speed machining, the real feedrate is often lower than the programmed one. This reduction of the feedrate is mainly due to the physical limits of the drives, and affects machining time as well as the quality of the machined surface. Indeed, if the tool path presents sharp geometrical variations the feedrate has to be decreased to respect the drive constraints in terms of velocity, acceleration and jerk. Thus, the aim of this paper is to smooth 5-axis tool paths in order to maximize the real feedrate and to reduce the machining time.Velocity, acceleration and jerk limits of each drive allow to compute an evaluation of the maximum reachable feedrate which is then used to localize the areas where the tool path has to be smoothed. So starting from a given tool path, the proposed algorithm iteratively smoothes the joint motions in order to raise the real feedrate. This algorithm has been tested in 5-axis end milling of an airfoil and in flank milling of an impeller for which a N-buffer algorithm is used to control the geometrical deviations. An important reduction of the measured machining time is demonstrated in both examples.

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Optimization of 5-axis high-speed machining using a surface based approach

Cited by 66 publications

References 24 publications

Towards efficient 5-axis flank CNC machining of free-form surfaces via fitting envelopes of surfaces of revolution

Towards efficient 5-axis flank CNC machining of free-form surfaces via fitting envelopes of surfaces of revolution

End mill tools integration in CNC machining for rapid manufacturing processes: simulation studies

5-Axis tool path smoothing based on drive constraints

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