Optimization of pocket machining strategy in HSM

Our two major concerns, which should be taken into consideration as soon as we start the selecting the machining parameters, are the minimization of the machining time and the maintaining of the high-speed machining machine in good state. The manufacturing strategy is one of the parameters which practically influences the time of the different geometrical forms manufacturing, as well as the machine itself. In this article, we propose an optimization methodology of the machining strategy for pockets of complex forms. For doing this, we have developed analytic models expressing the feed rate of the cutting tools trajectory. Then, we have elaborated an optimization method based on the analysis of the different critical parameters so as to distinguish the most suitable strategies to calculate the cutting time and define the machine dynamics. To validate our results, we have compared them to the experimental ones and also to those found in literature

Compensation of machining errors of Bspline and Cspline

The evolution of the interpolation methods towards a very high technicality requires a good choice of used type in the operation of high-speed milling (HSM). The “Bspline” and “Cspline” interpolations present good solutions to guarantee the tool’s continuous movement during machining. However, in a previous article, we have shown by a simulation tool that they generate significant dimensional errors that decrease the precision of the machined part. In this article, a method of compensating for these errors based on the insertion of the nodes, while respecting the predefined tolerance, has been developed. To do this, we have modeled and simulated machining errors before and after compensation for each type of interpolation. To validate our results,we have machined a test piece with the compensated and uncompensated Bspline and Cspline interpolations on theHuron KX10 machine and we have measured the corresponding machining errors. The results have shown that the method of compensation by the insertion of the nodes causes a significant reduction of the machining errors

Influence of interpolation type in high-speed machining (HSM)

The recourse to the high-speed machining for the manufacture of warped shapes imposes an evolution towards a very high technicality of the CAM methods and of the machining operation execution. Due to its own characteristics, the high-speed machining (HSM) implies the use of new machining interpolations, in such a way that it assures the continuity of advances in the best way possible. Among these interpolations, we mention the polynomial interpolation. In this article, we propose a complete study of the interpolation type influence on the HSM machine dynamic behavior and also on the generated errors. For this, we have measured the feed rate of the cutting tool path for each type. Then, in terms of accuracy, we have measured the errors. In order to validate our approach, we have compared the simulated results to the experimental ones

Simulation of machining errors of Bspline and Cspline.

The high-speed milling operation is widely used in industry for the production of aircraft parts, molds, and dies. The machining based on the polynomial programming (especially Bezier or basic spline (Bspline) and cubic spline (Cspline)) brings an interesting gain in cycle time. However, part quality can be degraded by using this type of programming. In this paper, we suggest a simulation methodology for errors caused by the interpolations: Bspline and Cspline in high-speed machining of warped shapes. To do this, we have developed analytical models expressing the basic paths of these interpolations. Then, we have designed a simulation tool based on these models. Experimental verifications have been done to validate our approac

Influence of the compensation method of machining errors of Bspline and Cspline

Contemporary advances in manufacturing are moving towards the diversification of interpolation methods in Computer Aided Manufacturing (CAM) softwares thanks to the growing need of freeforms of high quality. New interpolations such as ‘Bspline’ and ‘Cspline’ provide accurate toolpaths,but they generate significant machining errors. The nodes insertion technique is one of compensation methods of those errors. This paper presents a study of the influence of this compensation method on the manufacturing process: dynamic behavior of machine-tools, errors of controller, and surface quality. To make this study, Bspline and Cspline interpolations, errors generated, and the compensation method are defined. In addition to that, feed rate, cycle time and roughness before and after compensation are measured in order to exanimate the impact of the nodes insertion method. The present work aims to deliver a framework that demonstrates how manufacturing companies with such specific parameters optimization can improve smartness and machining efficiency

Surface roughness perfection by CAM interpolations

The surface quality of the parts is one of the major objectives of the use of the high-speed milling (HSM). Tool path interpolations affect the machining operation of complex parts in HSM. In this paper, the influence of the different types of interpolation of the computer-aided manufacturing (CAM) on the surface roughness in the HSM machining of free forms is studied. To do this, a simulation tool of the surface texture for each type of interpolation is proposed. Then, experimental measurements expressing surfaces condition are carried out. To validate our approach, theoretical results with experimental ones are compared. As results, CAM interpolations of tool paths have demonstrated an important impact on the surface texture. In fact, a simulation prediction tool has confirmed the advantages of using polynomial interpolations in order to ameliorate the quality of the machined surface

Modeling and simulation of high speed milling centers dynamics

High speed machining is a milling operation in industrial production of aeronautic parts, molds and dies. The parts production is being reduced because of the slowing down of the machining resulting from the tool path discontinuity machining strategy. In this article, we propose a simulation tool of the machine dynamic behavior, in complex parts machining. For doing this, analytic models have been developed expressing the cutting tool feed rate. Afterwards, a simulation method, based on numerical calculation tools, has been structured. In order to validate our approach, we have compared the simulation results with the experimental ones, for the same examples

Simulation Tool of the HSM machine dynamic behavior

High speed machining is a milling operation in industrial production of aeronautic parts, molds and dies. The parts production is being reduced because of the slowing down of the machining resulting from the tool path discontinuity machining strategy. In this article, we propose a simulation tool of the machine dynamic behavior, in complex parts machining. For doing this, analytic models have been developed expressing the cutting tool feed rate. Afterwards, a simulation method, based on numerical calculation tools, has been structured. In order to validate our approach, we have compared the simulation results with the experimental ones, for the same examples