Optimization of 5-Axis milling processes based on the process models with application to airfoil machining

5-axis milling is widely used in machining of complex surfaces such as airfoils. Improper selection of machining parameters may cause low productivity and undesired results during machining. There are several constraints such as available power and torque, chatter stability, tool breakage etc. In order to respect such constraints proper machining parameters should be determined. In this paper, methodologies for improving 5-axis milling processes are presented. Selection of machining parameters is performed using process simulations. The developed methodologies are presented on an example airfoil

Iso-level tool path planning for free-form surfaces

The aim of tool path planning is to maximize the efficiency against some given precision criteria. In practice, scallop height should be kept constant to avoid unnecessary cutting, while the tool path should be smooth enough to maintain a high feed rate. However, iso-scallop and smoothness often conflict with each other. Existing methods smooth iso-scallop paths one-by-one, which make the final tool path far from being globally optimal. This paper proposes a new framework for tool path optimization. It views a family of iso-level curves of a scalar function defined over the surface as tool path so that desired tool path can be generated by finding the function that minimizes certain energy functional and different objectives can be considered simultaneously. We use the framework to plan globally optimal tool path with respect to iso-scallop and smoothness. The energy functionals for planning iso-scallop, smoothness, and optimal tool path are respectively derived, and the path topology is studied too. Experimental results are given to show effectiveness of the proposed methods

ALPHA_I, Remote Manufacturing, and Solid Freeform Fabrication

Alpha_l is a nonuniform rational B-spline (NURBs) based solid modeling system that has been developed at the University of Utah over the past 10 years. In addition to being useful in modeling objects that are described by simple rotation and extrusion operations, the real power of Alpha_l is demonstrated in the modeling of complex parts with sculptured surfaces. For the past several years, a major research thrust has been to use Alpha_l to semi-automatically generate process plan information and numerical control code to manufacture mechanical parts directly from the models. A long term goal is to support an on-line remote manufacturing facility for producing prototype parts. Recently, a 3D Systems stereo lithography machine has been added to the advanced manufacturing laboratory. The stereo lithography process and other SFF techniques are of particular interest for supporting a remote manufacturing facility in that these processes are inherently much safer than numerically controlled machining. Special Alpha_l interfaces including a new slicing algorithm are being developed for the SFF machine use. By generating a SFF part directly from its NURBs description, Alpha_l should facilitate the manufacture of complex parts while providing smoother surfaces.Mechanical Engineerin

Precision sculptured surface CNC machining using cutter location data

Industrial parts with sculptured surfaces are typically, manufactured with the use of CNC machining technology and CAM software to generate surface tool paths. To assess tool paths computed for 3-and 5-axis machining, the machining error is evaluated in advance referring to the parameter controlling the linearization of high-order curves, as well as the scallop yielded as a function of radial cutting engagement parameter. The two parameters responsible for the machining error are modeled and corresponding cutter location data for tool paths are utilized to compare actual trajectories with theoretical curves on a sculptured surface assessing thus the deviation when virtual tools are employed to maintain low cost; whilst ensuring high precision cutting. This operation is supported by applying a flexible automation code capable of computing the tool path; extracting its CL data; importing them to the CAD part and finally projecting them onto the part’s surface. For a given tolerance, heights from projected instances are computed for tool paths created by changing the parameters under a cutting strategy, towards the identification of the optimum tool path. To represent a global solution rough machining is also discussed prior to finish machining where the new proposals are mainly applied.</jats:p

Highly effective way in five-axis sculptured surfaces machining using flat-end cutter

This paper applied the concept of “contact” in Differential Geometry into the machining of the sculptured surface. I presented the contact principle of the machining of complicated surfaces, using the circumference circle of the cylindrical cutter to sweep the curved surface instead of ball-end mill. This is highly effective method. In this paper an theory for machining complicated surface is presented. By using a flat-end mill instead of ball-end mill, and adjusting the axis relate to the surface, the two surfaces, The swept surface and the required surface, has the same curvature, up to as high as 3th order