Optimization of machining strip width using effective cutting shape of flat-end cutter for five-axis free-form surface machining

Wu, Baohai; Liang, Mancang; Zhang, Ying; Luo, Ming; Tang, Kai

doi:10.1007/s00170-017-0953-2

Cited by 18 publications

(3 citation statements)

References 14 publications

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“…Exksting research on flank milling is mainly about the minimization of machining errors. The corresponding issues include envelope surface [22][23][24][25], cutter-workpiece engagements [26][27][28][29][30], geometrical deviations [24,31,32], tool path planning strategies [33][34][35][36][37][38][39], tool path optimization with: particle swarm optimization method [40], dynamic programming method [41], local method [42], global method [43], constraints [44], generic cutters [45], the consideration of tool path smoothness [46], the influences of tool axis [47] and cutter runout [48,49], cutter optimization of shape [50] and size [51], etc. In contrast, the manufacturing of SBGs values the working performances [21], such as contact path and transmission errors.…”

Section: Introductionmentioning

confidence: 99%

An Efficient Approach to the Five-Axis Flank Milling of Non-Ferrous Spiral Bevel Gears

Xu¹,

Zhou

et al. 2021

Materials

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Five-axis flank milling has been applied in industry as a relatively new method to cut spiral bevel gears (SBGs) for its flexibility, especially for the applications of small batches and repairs. However, it still has critical inferior aspects compared to the traditional manufacturing ways of SBGs: the efficiency is low, and the machining accuracy may not ensure the qualified meshing performances. To improve the efficiency, especially for cutting non-ferrous metals, this work proposes an approach to simultaneously cut the tooth surface and tooth bottom by a filleted cutter with only one pass. Meanwhile, the machining accuracy of the contact area is considered beforehand for the tool path optimization to ensure the meshing performances, which is further confirmed by FEM (finite element method). For the convenience of the FEM, the tooth surface points are calculated with an even distribution, and the calculation process is efficiently implemented with a closed-form solution. Based on the proposed method, the number (or total length) of the tool path is reduced, and the contact area is qualified. Both the simulation and cutting experiment are implemented to validate the proposed method.

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Section: Introductionmentioning

confidence: 99%

An Efficient Approach to the Five-Axis Flank Milling of Non-Ferrous Spiral Bevel Gears

Xu¹,

Zhou

et al. 2021

Materials

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“…Software for generating complex curved tool paths is widely used, and popular programs include UG [31][32][33], PRO/E [34], and PowerMILL [35]. The main advantage of commercial software is that it can automatically generate tool paths flexibly according to the shape of a rough workpiece and a machining target.…”

Section: Introductionmentioning

confidence: 99%

Study of the tool path generation method for an ultra-precision spherical complex surface based on a five-axis machine tool

Xing

Zhao

Cui

et al. 2021

Int J Adv Manuf Technol

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The improvement of ultra-precision machining technology has significantly boosted the demand for the surface quality and surface accuracy of the workpieces to be machined. However, the geometric shapes of workpiece surfaces cannot be adequately manufactured with simple plane, cylindrical, or spherical surfaces because of their different applications in various fields. In this research, a method was proposed * Corresponding Author.

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“…However, real machining strip width and real residual height should be formed between two adjacent cutter contours. In order to solve the above problems, Baohai Wu et al presented and proved a more suitable method for computing machining strip width [4]. Rao et al examined the effect of feed on the machined surface for tool orientations using the Principal Axis Method (PAM).…”

Section: Introductionmentioning

confidence: 99%

A Tool Tilt Angle Calculation Method in 5-axis Flat-end Milling for Free Surface Machining

Jang¹,

Yu²,

Hwang³

et al. 2021

IJIMSE

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This paper proposes a method for calculating the tilt angle of the tool and the machining strip width when the tool is inclined to the feed direction. Tilt angle of the tool and machining strip width are important factors which affect feed rate and machining quality in five-axis flat-end milling for free surface. There are some methods to calculate the tilt angle of the tool in five-axis flat-end milling for free surface, but mathematically complicated algorithm is applied to the calculation of tilt angle of the tool, so it is difficult to apply it in practice. We considered the geometry of the surface and the tool as well as the scallop height to determine the tool tilt angle, thus ensuring the tool to be contacted with the surface at two points. This allows us to calculate the tool tilt angle and the machining strip width by solving quadric equations based on the contact circle. Moreover, tool tilt angle and machining strip width are calculated analytically. Thus the speed of calculation is quick and easy to implement. An experiment of machining on the biquantic B-spline surface was performed and the results show that the proposed method has considerably higher machining efficiency than the CMM.

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Optimization of machining strip width using effective cutting shape of flat-end cutter for five-axis free-form surface machining

Cited by 18 publications

References 14 publications

An Efficient Approach to the Five-Axis Flank Milling of Non-Ferrous Spiral Bevel Gears

An Efficient Approach to the Five-Axis Flank Milling of Non-Ferrous Spiral Bevel Gears

Study of the tool path generation method for an ultra-precision spherical complex surface based on a five-axis machine tool

A Tool Tilt Angle Calculation Method in 5-axis Flat-end Milling for Free Surface Machining

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