Tool Posture Determination for 5-Axis Control Machining by Area Division Method

Abstract

The study deals with a new method to generate interference-free tool posture for 5-axis control machining using a ball end-mill. The 5-axis control machining can produce complicated shapes and parts consisting of overhanging and or sculptured surfaces such as impellers. However, high degree of freedom of 5-axis control machining center causes a fatal problem that other parts except cutting edges of the tool may interfere with other surfaces of the machining object. Therefore, it is necessary to obtain the adequate tool postures to avoid the interference during machining. The interference avoidance is generally performed by the method that cutting points are generated so as to be arranged on the surface to be machined, and then the interference-free tool posture is determined on each cutting point by the geometrical calculations. However, the method has a problem that it takes long time for calculation. To solve the problem, the study proposes a new interference avoidance method of reversing the order of the above procedure, i.e., that of determining a set of interference-free tool postures before generating cutting points. From the machining results, it is confirmed that the proposed method is available to fabricate complicated shapes since the impeller can be machined by using the method.

Iterative learning contouring controller based on trajectory generation with linearly interpolated contour error estimation and Bézier reposition trajectory for computerized numerical control machine tool feed drive systems

“…Highly accurate mechanical components with highcurvature surface are widely required in the fields of aerospace, energy, power, medical, and automobile, such as knee joints, 1 propellers, 2 impellers with small splitter blades, [3][4][5] gears, 6 and ship structural components. 7 To produce such components, many engineers choose the computerized numerical control (CNC) machining process, which has advantages of high production efficiency, high machining precision, and stable product quality.…”

A physically-based model for global collision avoidance in 5-axis point milling

“…In most cases, the tool is divided into implicit surfaces (cylinders, cones) [1] leading to the description of the tool under the APT formalism [2]. The check surface, usually designed in the CAD system by a parametric surface, is modeled as a NURBS surface [3] by its convex envelope [4] or by a tessellated representation to simplify computations.…”

A Review of the Main Modeling Methods for Ball Nose End Milling Processes

“…The modeling of the cutting processes always has been a preoccupation of the researchers in the field of metal cutting [1], [2], [3], [4], [5], [6], [7], [8], [9], [10], [11], [12], [13], [14], [15], [16], [17], [18], [19].…”