Development of Algorithms to Represent Intermediate Layers for Machining Sculptured Surfaces

The objective aim of this research is to develop an algorithm for design and manufacture sculptured surfaces that are common in a wide variety of products such as dies, automobile, and aircrafts components. In the design stage Bezier technique has been used to represent the desire surface. In rough-machining stage, the number of intermediate layers depend on the geometry of the desired surface and on the maximum allowable depth of cut, an algorithm has been proposed to represent these layers, whereas another efficient algorithm has been proposed to represent the semifinished layer depends on the tangents and normal vectors along all the points of the desired surface to create the offset surface. The desired surface generated points using Bezier technique are used as cutter location points for the finish machining tool path. Flat end mill (φ 12mm) has been used for the intermediate stages machining (roughing), while (φ 12mm) ball end mill have been used for both semi-finish and finish machining. The developed algorithm have been tested by several designed sculptured surfaces, its proved good flexibility and efficiently in all of its stages, the results have been implemented for machining one of these surfaces [fifteen intermediate layers, semi-finished layer, and finished] using 3-axis vertical CNC machine. The proposed rough machining algorithm reduces the machining time as compared with contour tool path by 15% for case study two and reduces the NC file size 52% for case study three

From computer-aided to intelligent machining: Recent advances in computer numerical control machining research

The aim of this paper is to provide an introduction and overview of recent advances in the key technologies and the supporting computerized systems, and to indicate the trend of research and development in the area of computational numerical control machining. Three main themes of recent research in CNC machining are simulation, optimization and automation, which form the key aspects of intelligent manufacturing in the digital and knowledge based manufacturing era. As the information and knowledge carrier, feature is the efficacious way to achieve intelligent manufacturing. From the regular shaped feature to freeform surface feature, the feature technology has been used in manufacturing of complex parts, such as aircraft structural parts. The authors’ latest research in intelligent machining is presented through a new concept of multi-perspective dynamic feature (MpDF), for future discussion and communication with readers of this special issue. The MpDF concept has been implemented and tested in real examples from the aerospace industry, and has the potential to make promising impact on the future research in the new paradigm of intelligent machining. The authors of this paper are the guest editors of this special issue on computational numerical control machining. The guest editors have extensive and complementary experiences in both academia and industry, gained in China, USA and UK