A Reliable and Efficient Approach to Numerically Controlled Programming Optimization for Multiple Largest Tools Cutting Blisks Patch by Patch in the Blisks' Four-Axis Rough Machining

2017 ◽  
Vol 139 (9) ◽  
Author(s):  
Zhiyong Chang ◽  
Jinan Wen ◽  
Zezhong C. Chen ◽  
Dinghua Zhang
Keyword(s):  
Large Diameter ◽  
Small Diameter ◽  
Surface Patch ◽  
Free Form ◽  
Cnc Machine ◽  
Rough Machining ◽  
Cnc Machines ◽  
End Mills ◽  
Five Axis ◽  
Free Form Surfaces

As an important component of gas turbine engines, a blisk (or an axial compressor) is complex in shape. The pressure and suction surfaces of the blisk blades are designed with free-form surfaces, and the space (or the channel) between two adjacent blades varies significantly. Thus, some blade patches can be machined with large-diameter cutters, and some patches have to be cut with small-diameter cutters. Usually, the blisk's material is high-strength stainless steel, titanium alloy, or difficult-to-cut material. The cutting force and temperature in roughing the blisks are high, and thus, the machine tool should be rigid and the cutters should be as large as possible. Therefore, the best industrial practice of rough-machining the blisks is to use multiple largest solid and indexable end-mills to cut them patch by patch on a four-axis computer numerically controlled (CNC) machine. The reasons are (a) four-axis CNC machines are more rigid than five-axis CNC machines, (b) multiple largest cutters are used for higher cutting speeds and feed rates and for less machining time and longer tool life, and (c) if indexable end-mills can be used, the tooling costs are further reduced. For the blisk finishing, a small cutter is often used on a five-axis CNC machine, which is not a topic of this work. However, due to complex shape of the blades, it is quite difficult to automatically optimize the blade surface partition so that each surface patch can be cut with a largest cutter in four-axis blisk rough machining. In the conventional way, numerically controlled (NC) programmers often employ small-diameter solid end-mills and plan their paths to cut the blades layer by layer in four-axis milling. Unfortunately, the machining efficiency of this way is low, and the end-mills wear out quickly. This work establishes a theoretical and completed solution. A simplified optimization model of the largest allowable diameter of the theoretical cutter at a cutter contact (CC) point is established, and an efficient and reliable solver is proposed. The blade surfaces are automated partitioned for largest cutters to the surfaces patch by patch in four-axis rough machining. This approach is efficient and reliable, and it is viable in theory and practical in industry.

scholarly journals The method for evaluation errors of automated measurements of base tangent length by three-axis indicator on five-axis CNC machine

2021 ◽  
pp. 35-43
Author(s):  
D. T. Safarov ◽  
◽  
A. G. Kondrashov ◽  
Keyword(s):  
Statistical Methods ◽  
Systematic Errors ◽  
Random Errors ◽  
Cnc Machine ◽  
Cnc Machines ◽  
Automated Measurements ◽  
Periodic Monitoring ◽  
End Mills ◽  
Systematic And Random Errors ◽  
Five Axis

The article provides an overview of studies of various errors in the process of measuring parts with three-coordinate probes on CNC machines. The paper considers a method for estimating systematic and random errors in the process of measuring the length of the base tangent using control maps and probabilistic and statistical methods for processing multiple repeated inputs of a three-coordinate indicator to the measured side surfaces of the wheel teeth. The method is designed to assess the acceptability of the measurement process by technologists and adjusters. The data of experimental estimation of random and systematic errors of measurement of the length of the base tangent on a five-coordinate CNC machine with a three-coordinate indicator of Mahr are presented. The obtained error values for the five-axis machine under study allow us to measure the length of the base tangent for the purposes of periodic monitoring and adjustment of the machine when processing oblique cylindrical wheels with universal disk or end mills

An Approach to the Low-Cost Computer Aided Manufacture of Components Embodying Free-Form Surfaces

1989 ◽  
Vol 203 (2) ◽  
pp. 119-126 ◽  
Author(s):  
X Gao ◽  
D K Harrison ◽  
B J Davies
Keyword(s):  
Computer Aided Design ◽  
Numerical Control ◽  
Personal Computers ◽  
Surface Patch ◽  
Free Form ◽  
Height Determination ◽  
Computer Aided ◽  
Cusp Height ◽  
Five Axis ◽  
Free Form Surfaces

The numerical control (NC) machining of free-form surfaces is usually accomplished utilizing minicomputer or mainframe computer aided design and manufacturing (C ADC AM) systems. The resulting NC data are suitable for either three-axis or five-axis machining dependent upon machine tool type/capability and CAM package complexity. However, the cost of such packages and systems precludes the use of these in smaller companies with an occasional requirement for components embodying free-form surfaces. The increasing availability of powerful yet reasonably priced personal computers (PC) coupled with improving software provides such companies with a far cheaper alternative approach. However, a common feature of PC-based CADCAM systems is that they are limited to 2 1/2-axis machining for all but special applications such as three-axis canted Z-plane milling of four-axis wire electro discharge machining (EDM). This paper presents a method for manufacturing true three-dimensional free-form surfaces using PC-based 2 1/2-axis CADCAM systems. All the main functions performed on mainframe systems can be performed on personal computers, such as toolpath generation for free-form surfaces, cusp height determination and change in shape and volume which may be used for the compensation of shrinkage or to suit market requirements. This is significant for manufacturers who make use of moulds, such as are found in the plastic processing industries. The manufacture of a blown plastic bottle mould is presented as a typical example. The inclusion into the PC environment of features to be found in mainframe systems is also discussed, such as machining the surface patch by patch in any direction or machining a number of patches at one time, shape and volume change in any direction, cusp height determination, etc.

scholarly journals DYNAMICS OF FIVE-AXIS END MILLING PROCESS

2019 ◽  
Vol 4 (7) ◽  
pp. 108-120
Author(s):  
Б. Пономарев ◽  
Boris Ponomarev ◽  
Хьен Нгуен ◽  
Hien Nguyen
Keyword(s):  
Cutting Forces ◽  
End Milling ◽  
Milling Process ◽  
Free Form ◽  
Machine Model ◽  
End Mills ◽  
Tool Position ◽  
Five Axis ◽  
Free Form Surfaces ◽  
End Milling Process

The article presents the experimental results of the influences of machining conditions and tool orientation on cutting forces during the end milling of free-form surfaces. A series of experiments are carried out on the machining of steel 3 blanks on a five-axis milling machine model HSC 75 linear using 2-flute and 4-flute ball end mills from MITSUBISHI with diameters from 5 mm to 10 mm. The dependency diagrams and graphs of cutting forces and their projections on cutting time are given at different spindle speeds, feeds per tooth, depths of cut, tilt angles and lead angle when using different ball end mills. Based on the results of the analysis of experimental data, the theoretical conclusion about the increase in cutting forces with increasing feed per tooth, cutting depth and spindle speed in relation to the ball end milling process is confirmed. The critical tool positions with respect to the surface, at which cutting forces have maximum values, are revealed. The obtained results allow developing recommendations for the choice of the tool position during end milling of free-form surfaces to reduce loads on the tool

Finding Cutter Engagement for Ball End Milling of Tessellated Free-Form Surfaces

2005 ◽  
Author(s):  
Zhiyang Yao
Keyword(s):  
Surface Finish ◽  
Feed Rate ◽  
End Milling ◽  
Geometric Algorithms ◽  
Free Form ◽  
Ball End Milling ◽  
Final Surface ◽  
End Mills ◽  
Free Form Surfaces ◽  
Final Surface Finish

In fabricating free-form surfaces, ball end mills are mainly used to reach the final surface finish requirements. In the milling processes, cutter engagement value measures what portion of the cutter is involved in machining at a given instant of time. This paper presents geometric algorithms for estimating cutter engagement values for ball end milling processes of tessellated free-form surfaces. The cutter engagement value calculated here can be used later on in generating efficient cutter paths, as well as performing adaptive feed rate controls.

Adaptive Tool Path Planning Strategy for 5-Axis CNC Machining of Free Form Surfaces

2019 ◽  
Author(s):  
Hrishikesh Mane ◽  
S. S. Pande
Keyword(s):  
Tool Path ◽  
Cnc Machining ◽  
Memory Storage ◽  
Free Form ◽  
Cnc Machine ◽  
Planning Strategy ◽  
Part Quality ◽  
Tool Paths ◽  
Path Topology ◽  
Free Form Surfaces

Abstract This paper presents a curvature based adaptive iso-parametric strategy for the efficient machining of free form surfaces on 5-axis CNC machine using the flat end mill tool. One iso-parametric boundary of the surface is selected as the initial tool path. Set of cutter contact (CC) points are chosen adaptively on the initial tool path considering desired profile tolerance. Adjacent iso-parametric tool paths are computed adaptively based on the scallop height constraint unlike the traditional iso-parametric approach. The path topology is post-processed to generate the part program for 5-axis CNC machine in ISO format. The system was rigorously tested for various case studies by comparing the results with the traditional 5-axis iso-parametric tool path strategy, iso-scallop strategy and iso-planar strategy of a commercial software. Our system was found to generate efficient tool paths in terms of part quality, productivity and memory storage compared to the conventional strategies.

The Research of Five-Axis NC High Efficient Machining Technology for UAV Integral Impeller

2014 ◽  
Vol 598 ◽  
pp. 189-193
Author(s):  
Hui Zhao ◽  
Yu Jun Cai ◽  
Guo He Li
Keyword(s):  
Process Analysis ◽  
Coordinate Measuring Machine ◽  
Machining Process ◽  
Machining Parameters ◽  
Program Optimization ◽  
Cnc Machine ◽  
Rough Machining ◽  
High Efficient ◽  
Measuring Machine ◽  
Five Axis

In this paper, a very detailed process analysis for UAV integral impeller was made. According to the specific processing requirements, the appropriate CNC machine, blank and cutting tools have been choosing. In the rough machining process, various machining strategies have been used for comparing and analyzing, finally a more efficient roughing method with the accurate machining parameters will be obtained. At the same time the machining method have been improved and the processing parameters also have been determined in the semi-finishing process. Through the simulation processing in VERICUT, the possibility of the existence of interference which is usually occurred in the actual processing can be ruled out and the program optimization will be finished in the meantime. Finally, using intelligent three-coordinate measuring machine the consequence will be verified and inspected in the actual machining process.

Rough machining of free-form surfaces defined by dual kriging

1996 ◽  
Vol 34 (6) ◽  
pp. 1603-1623 ◽  
Author(s):  
F. TROCHU ◽  
Y. ABONG ◽  
M. BALAZINSKI ◽  
P. LARBRISSEAU
Keyword(s):  
Free Form ◽  
Rough Machining ◽  
Dual Kriging ◽  
Free Form Surfaces

Discretizors and Interpolators for Five-Axis CNC Machines

1999 ◽  
Vol 122 (1) ◽  
pp. 191-197 ◽  
Author(s):  
Radha Sarma ◽  
Aarthi Rao
Keyword(s):  
Discrete Time ◽  
Sampling Period ◽  
Cnc Machine ◽  
Time Intervals ◽  
New Techniques ◽  
Cnc Machines ◽  
Complex Curves ◽  
Computer Numerically Controlled ◽  
Five Axis

Discretization and interpolation of curves are two frequently adopted practices when machining complex curves using computer numerically controlled (CNC) machines. Both practices stem from the need to sample curves at discrete time intervals corresponding to the sampling period of the CNC machine. This paper proposes new techniques for discretization and interpolation that account for the change of tool orientations in five-axis machining. First, the method for discretization proposed in this paper is based on sampling the curves such that specified contour, feedrate, and orientation errors are not exceeded. Second, the interpolator proposed in this paper will be able to avoid excessive angular speeds arising from sampling the curves based on the feedrate alone. [S1087-1357(00)01401-5]

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