Preferred feed direction field: A new tool path generation method for efficient sculptured surface machining

Kumazawa, Guillermo Hiroki; Feng, Hsi-Yung; Fard, M. Javad Barakchi

doi:10.1016/j.cad.2015.04.011

Cited by 47 publications

(14 citation statements)

References 30 publications

(34 reference statements)

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“…In order to determine this, vector PC * should be rotated around point P by an angle of α = 90 ∘ − θ. Using a vector field solution method that yielded the desired feed direction at different points of surface, Kumazawa et al [51] developed a 3D surface finishing tool path. The above-described approach could be extended to all P points situated within the distance r tool as measured from the contour.…”

Section: New Methods Of Generating Tool Paths For General Planar Contoursmentioning

confidence: 99%

The fast constant engagement offsetting method for generating milling tool paths

Jacsó

Mátyási

Szalay

2019

Int J Adv Manuf Technol

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It is a well-established fact that when equidistant tool paths are used for 2.5D milling operations tool load varies based on the functions of path curvature. This phenomenon makes the optimal selection of cutting parameters more difficult, and the local load peaks are also detrimental to machining stability and tool life. Numerous publications address possible solutions to eliminate the problems caused by varied cutting parameters. The best solution for this is to keep the cutter engagement at a constant value. Nowadays, several methods are available to generate tool paths which are able to maintain constant cutter engagement, but the widespread use of such solutions is significantly hindered, because in this scenario complex calculations are required. This article offers a solution to this problem by presenting a new non-equidistant offsetting method for ensuring a constant cutter engagement angle. The algorithm developed for this purpose is based on simple geometrical equations and allows for its widespread use just like pixel-based methods. Concerning this new solution, computation needs and uniform tool load are verified by simulation and through experiments. The experiments have shown favourable results. Keywords Tool path generation. Cutter engagement. High-speed milling. Cutting force. Non-equidistant offsetting Nomenclature a e Effective radial immersion [mm] a p Axial depth of cut [mm] c(t) Parametric representation of workpiece contour [{mm, mm}] f z Feed per tooth [mm] h ex Maximum chip thickness [mm] i, j Step index [−] n Spindle speed [1/min] p(t) Parametric representation of tool path [{mm, mm}] r tool Tool radius [mm] s Stepover [mm] t Free parameter of curve equations [−] v Feed vector [{mm, mm}] v c Cutting speed [m/min] v f Feed rate [mm/min] w Trochoidal step [mm] z Number of teeth [−] C Entry point of the cutting edge [{mm, mm}] D tool Tool diameter [mm] MRR Material removal rate [mm 3 /min] P Tool path point [{mm, mm}] Q Exit point of cutting edge [{mm, mm}] V(x, y) Vector field [{mm, mm}, {mm, mm}] a, β Angle parameters [ ∘ ] Δs Stepsize[−] θ Cutter engagement angle [ ∘ ]

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Section: New Methods Of Generating Tool Paths For General Planar Contoursmentioning

confidence: 99%

The fast constant engagement offsetting method for generating milling tool paths

Jacsó

Mátyási

Szalay

2019

Int J Adv Manuf Technol

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“…The preferred feed direction (PFD) method (Kumazawa, Feng, and Barakchi Fard 2015) is designed to maximise the cutting strip. The PFD field is partitioned into the subregions by identifying the degenerate points and generating the separatrices.…”

Section: Introductionmentioning

confidence: 99%

Five-axis machining of STL surfaces by adaptive curvilinear toolpaths

Moodleah

Bohez

Makhanov

2016

International Journal of Production Research

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We propose a new framework for toolpath generation for five-axis machining of part surfaces represented by the StereoLithography (STL) format. The framework is based on flattening the STL part and generation of adaptive curvilinear toolpaths. The corresponding cost functions, designed to represent the accuracy and the efficiency of the toolpath, are scalar functions, such as the curvature, kinematic error, rotation angles, machining strip or material removal rate or a vector field when the tool moves along a curvilinear path partly or even entirely aligned with directions considered to be optimal. The adaptive toolpath exploits grid generation methods and biased space-filling curves, combined with adaptation to the boundary and the domain decomposition. The proposed methodology of the adaptive curvilinear toolpath (ACT) has been tested on a variety of STL surfaces, including a case study of STL dental parts. Machining crowns/ implants for four basic types of human teeth, molar, premolar, canine and incisor, has been considered and analysed. The reference methods are the standard iso-parametric path, MasterCam toolpath, and advanced methods of NX9 (former UG). The experiments show that there is no universal sequence of steps applicable to every surface. However, a correct choice of the tools available within the proposed ACT-framework always leads to a substantial improvement of the toolpath, in terms of its length and the machining time.

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“…The mold and die industry occupies a key position in the manufacturing chain, affecting costs, quality and delivery time of a product [1,2]. In addition, in order to meet market demand related to product aesthetics and complexity, designers have used curved geometries to shape products, which increase the complexity and duration of manufacturing [3][4][5].…”

Section: Introductionmentioning

confidence: 99%

Influence of feed direction on finishing milling cylindrical surfaces in H13 hardened steel

Magalhães

Ferreira

Bezerra³

et al. 2019

J Braz. Soc. Mech. Sci. Eng.

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CNC milling of curved surfaces is a common task in the manufacture of molds and dies of products used in various industrial sectors. Notably, in recent years, the use of hard milling has helped manufacturers to obtain these parts with shorter lead times, since the part is machined in a single setup without the problems caused by part distortions from the tempering process. In this work, cylindrical surfaces were machined in AISI H13 steel tempered and annealed to 52 HRC using hard milling and high speed milling concepts in the finishing stage. The cutting tool was feed along either upward ramping or downward ramping directions, and the quality of the texture of the obtained surfaces was evaluated as well as the wear of the ball nose cutter. The results showed that the surface is deteriorated when milling is performed in the downward direction (surface roughness equal to 6.93 μm) compared with the upward direction (2.17 μm). Also, vibration marks are present on the machined surface in the downward direction. In addition, surface roughness is worsened when the tool performs the cut primarily at regions away from the center of the tip of the ball nose cutter. On the other hand, the surface roughness is worsened when cutting with regions near the center of the tip of the ball nose cutter when milling in the upward direction. It was noticed that flank wear in both upward and downward directions was low (less than 10 μm), and micro-chipping was observed in the cutting edges.

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Preferred feed direction field: A new tool path generation method for efficient sculptured surface machining

Cited by 47 publications

References 30 publications

The fast constant engagement offsetting method for generating milling tool paths

The fast constant engagement offsetting method for generating milling tool paths

Five-axis machining of STL surfaces by adaptive curvilinear toolpaths

Influence of feed direction on finishing milling cylindrical surfaces in H13 hardened steel

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