Geometry and tool motion planning for curvature adapted CNC machining

CNC machining is the leading subtractive manufacturing technology. Although it is in use since decades, it is far from fully solved and still a rich source for challenging problems in geometric computing. We demonstrate this at hand of 5-axis machining of freeform surfaces, where the degrees of freedom in selecting and moving the cutting tool allow one to adapt the tool motion optimally to the surface to be produced. We aim at a high-quality surface finish, thereby reducing the need for hard-to-control post-machining processes such as grinding and polishing. Our work is based on a careful geometric analysis of curvature-adapted machining via so-called second order line contact between tool and target surface. On the geometric side, this leads to a new continuous transition between “dual” classical results in surface theory concerning osculating circles of surface curves and oscu- lating cones of tangentially circumscribed developable surfaces. Practically, it serves as an effective basis for tool motion planning. Unlike previous approaches to curvature-adapted machining, we solve locally optimal tool positioning and motion planning within a single optimization framework and achieve curvature adaptation even for convex surfaces. This is possible with a toroidal cutter that contains a negatively curved cutting area. The effectiveness of our approach is verified at hand of digital models, simulations and machined parts, including a comparison to results generated with commercial software

A review of dynamics design methods for high-speed and high-precision CNC machine tool feed systems

With the development of CNC machine tools toward high speed and high precision, the traditional static design methods can hardly meet the demand. Hence, in this paper, the dynamics matching design methods of existing CNC machine tool feed systems were investigated and analyzed. Further, sub-system coupling mechanisms and optimization design studies were carried out for each sub-system. First, the required kinematic indexes must be achieved when designing the feed system dynamics of high-speed, high-precision CNC machine tools. Second, the CNC machine tool feed systems generally have four sub-systems: motion process, control system, motor, and mechanical structure. The coupling effect between the sub-systems should also be considered in the design. Based on the dynamics design, each sub-system should be optimized to maximize the system dynamic performance with minimum resource allocation. Finally, based on the review, future research directions within the field were detected

Multiresolution analysis as an approach for tool path planning in NC machining

Wavelets permit multiresolution analysis of curves and surfaces. A complex curve can be decomposed using wavelet theory into lower resolution curves. The low-resolution (coarse) curves are similar to rough-cuts and high-resolution (fine) curves to finish-cuts in numerical controlled (NC) machining.;In this project, we investigate the applicability of multiresolution analysis using B-spline wavelets to NC machining of contoured 2D objects. High-resolution curves are used close to the object boundary similar to conventional offsetting, while lower resolution curves, straight lines and circular arcs are used farther away from the object boundary.;Experimental results indicate that wavelet-based multiresolution tool path planning improves machining efficiency. Tool path length is reduced, sharp corners are smoothed out thereby reducing uncut areas and larger tools can be selected for rough-cuts

The Development of Intelligent Machining-error Detector for Machining Sculptured Surfaces using 3 or 5 Axes CNC Milling Machine

A report submitted by Rachmawati Wangsaputra to the Research and Creative Productions Committee in 2005 on generating tool paths for machining sculptured surfaces

Design and manufacturing concepts for thermoplastic structures

Results to date on the application of two manufacturing techniques, fiber placement and single diaphragm/coconsolidation, to produce cost-effective, thermoplastic composite (TPC), primary fuselage structure are presented. Applications relative to fuselage upper cover structure indicate potential cost savings relative to conventional approaches. Progress is also presented on efforts concerned with other design details which take advantage of thermoplastic composites such as fastener less stiffener/frame attachments. In addition, results are presented on the development and verification testing of a composite lug analysis program which incorporates through-the-thickness effects

Material cutting, shaping, and forming: A compilation

Information is presented concerning cutting, shaping, and forming of materials, and the equipment and techniques required for utilizing these materials. The use of molds, electrical fields, and mechanical devices are related to forming materials. Material cutting methods by devices including borers and slicers are presented along with chemical techniques. Shaping and fabrication techniques are described for tubing, honeycomb panels, and ceramic structures. The characteristics of the materials are described. Patent information is included

Reliability Analysis of On-Demand High-Speed Machining

Current trends in high-speed machining aim to increase manufacturing efficiency by maximizing material removal rates and minimizing part cycle times. This project explores three related technologies and presents a system design for rapid production of custom machined parts. First a reliability analysis in high-speed machining of thin wall features is put forth with experimental results. Second an implementation of on-demand manufacturing is presented with emphasis on flexibility and automation. Finally innovative manufacturing cell design is used to drive costs down by optimizing material and information flow. The resulting high-speed on-demand machining cell design employs effective techniques to reduce production time, meet changing customer needs, and drive down costs