Rolling ball method for 5-axis surface machining

Integrated method for tool path generation in five-axis sculptured surface machining

“…In the local methods (Vickers and Quan 1989, Bedi et al 1997, Rao and Sarma 2000, Jensen et al 2002, Yoon et al 2002, only normal curvatures of C (or W i ) and S are considered to orient C. The main disadvantage of the local methods is that there could still be rear gouging, and consequently a secondary iterative gouge-check and correction algorithm has to be implemented (Gray et al 2005). The global methods overcome the disadvantage by using an area of S beneath C to determine the orientation (Warkentin et al 2000, Gray et al 2003, Hosseinkhani et al 2007, Fan and Ball 2008. In particular, the quadric method (QM) (Fan and Ball 2008) exploits fully the orientation angles (α, β) with respect to the machined strip width w. Further, the width evaluation is involved in the method, and its approximation error is conservative and acceptably small.…”

“…Table 2 compares of the IM with some alternative machining strategies introduced in Section 1.2 for machining the inverse mouse surface, and figure 8 illustrates the corresponding machined strips in parametric space. In some published 5-axis machining methods (Gray et al 2003, Hosseinkhani et al 2007, the screw angle β is kept at 0 • and the lead angle α is optimised by placing the cutter as close as possible to the design surface. The computational time for this method to generate 24 tool passes to cover the The example illustrates the potential efficiency savings of the IM compared to the other strategies, with reductions in the machining times of 33% and 68% respectively.…”

Reducing fluctuation of machining strip width by tool position modification for five-axis NC machining of sculptured surfaces

“…Numerical methods have been increasingly applied in tool positioning algorithms to avoid the problems caused by local differential geometry. Rolling ball method (RBM) [12,13] placed the cutter inside a ball's surface, Arc intersect method (AIM) [14] forced the forward pseudo insert to contact the surface at CC point and then tilted the tool until it touched a second point on the part surface, and Penetration-elimination method (PEM) [15] developed a quantitative definition for gouging concept and greatly reduced the computational burden. The middle-point error control (MPEC) method, which focuses on the error distribution between the cutter and surface, is introduced in this paper.…”

A global cutter positioning method for multi-axis machining of sculptured surfaces

“…Inspired by the progress, a lot of new cutter positioning methods have been presented subsequently [7][8][9][10][11][12]. However, despite of some improvement, no other methods was as creative and wonderful as the method of Strutz.…”