Geodesic Distance Field-based Process Planning for Five-Axis Machining of Complicated Parts

2020 ◽  
pp. 1-27
Author(s):  
Dong He ◽  
Yamin Li ◽  
Zhaoyu Li ◽  
Kai Tang
Keyword(s):  
Process Planning ◽  
Geodesic Distance ◽  
Machining Process ◽  
Rough Machining ◽  
Distance Field ◽  
Tool Paths ◽  
Solid Part ◽  
Level Method ◽  
Machining Operations ◽  
Five Axis

Abstract A critical task in multi-pass process planning for five-axis machining of complicated parts is to determine the intermediate surfaces for rough machining. Traditionally, the intermediate surfaces are simply parallel Z-level planes, and the machining is of the simplest three-axis type. However, for complicated parts, this so-called Z-level method lacks flexibility and causes isolated islands on layers, which require extraneous air movements by the tool. Moreover, the in-process workpiece machined according to the Z-level method suffers from the staircase effect, which often induces unstable dynamic problems on the tool-spindle system. In this paper, we propose a new method of planning a five-axis machining process for a complicated freeform solid part. In our method, the intermediate surfaces are no longer planar but curved, and they are intrinsically influenced by the convex hull of the part. The powerful algebraic tool of geodesic distance field is utilized to generate the desired intermediate surfaces, for which collision-free five-axis machining tool paths are then planned. In addition, we propose a novel idea of alternating between the roughing and finishing machining operations, which helps improve the stiffness of the in-process workpiece. Ample physical cutting experiments are performed, and the experimental results convincingly confirm the advantages of our method.

Generating STEP-NC Files for a Circuit Board Milling System

2012 ◽  
Vol 430-432 ◽  
pp. 1686-1691
Author(s):  
Ke Wang ◽  
Cheng Rui Zhang ◽  
Ri Liang Liu ◽  
Xiang Zhi Zhang
Keyword(s):  
Process Planning ◽  
Manufacturing Industry ◽  
Circuit Board ◽  
Machining Features ◽  
Tool Paths ◽  
Face Contour ◽  
Modern Manufacturing ◽  
Machining Operations ◽  
Parallel Strategy

Since G-codes have been proved limiting the modern manufacturing industry, ISO14649 was put forward. This paper presents a solution to generate ISO14649 files for circuit board milling. The process planning is given, and all the processes needed are contained in the ISO14649 file. Features and machining operations are identified for each process, such as the closed pocket having a “General_closed_profile” attribute and bosses, round holes, slots, the planar face, contour parallel strategy, contour bidirectional strategy and etc. The scenario of one feature with multi tools are put forward to promote the milling efficiency and an entity “Combined_Machining_workingsteps” is proposed. Besides, some other extensions are made, such as entities for representing circuit geometries in machining features. Algorithms for tool paths generation are demonstrated for contour parallel milling and bidirectional milling, where a new algorithm based on pixels is used. The new algorithm can be used in other functions such as detecting uncut regions.

A Voxel Model-Based Process-Planning Method for Five-Axis Machining of Complicated Parts

2020 ◽  
Vol 20 (4) ◽  
Author(s):  
Yamin Li ◽  
Kai Tang ◽  
Long Zeng
Keyword(s):  
Process Planning ◽  
Planning Method ◽  
Dynamic Problems ◽  
Tool Paths ◽  
New Process ◽  
Part Surface ◽  
Voxel Model ◽  
Voxel Representation ◽  
Complex Features ◽  
Five Axis

Abstract This paper presents a new process planning method for five-axis machining, which is particularly suitable for parts with complex features or weak structures. First, we represent the in-process workpiece as a voxel model. Facilitated by the voxel representation, a scalar field called subtraction field is then established between the blank surface and the part surface, whose value at any voxel identifies its removal sequence. This subtraction field helps identify a sequence of intermediate machining layers, which are always accessible to the tool and are free of self-intersection and the layer redundancy problem as suffered, respectively, by the traditional offset layering method and the morphing method. Iso-planar collision-free five-axis tool paths are then determined on the interface surfaces of these machining layers. In addition, to mitigate the deformation of the in-process workpiece and avoid potential dynamic problems such as chattering, we also propose a new machining strategy of alternating between the roughing and finishing operations, which is able to achieve a much higher stiffness of the in-process workpiece. Ample experiments in both computer simulation and physical cutting are performed, and the experimental results convincingly confirm the advantages of our method.

High Efficiency Machining for Integral Shaping from Simplicity Materials Using Five-Axis Machine Tools

2016 ◽  
Vol 10 (5) ◽  
pp. 804-812 ◽  
Author(s):  
Makoto Yamada ◽  
◽  
Tsukasa Kondo ◽  
Kai Wakasa
Keyword(s):  
Machine Tools ◽  
High Speed ◽  
High Efficiency ◽  
Cutting Process ◽  
Machining Process ◽  
Rough Machining ◽  
Convex Shape ◽  
Simple Material ◽  
Voxel Model ◽  
Five Axis

In the integrally shaping process from a simple material shape to an objective shape, it is necessary to reduce the time required for the machining process in order to improve cost savings and the effectiveness of mass production. For the purpose of achieving high efficiency in the integral shaping from simplicity materials, we have focused on a rough cutting process that requires the most time in the manufacturing process. The purpose of this research is to propose a method for realizing high-speed rough machining using five-axis machine tools with a voxel model, and confirm the high efficiency of the rough cutting. In this research, we use five-axis controlled machine tools for material machining, and suggest two machining methods for the rough cutting process using the voxel model. The first method derives the tool posture where the cutting removal quantity becomes the maximum; this method also carries out a rough cutting process via 3+2 axis controlled machining. The other method carries a complete convex shape that includes the required shape, and simultaneously machines via five-axis machining based on the complete convex shape. This paper demonstrates the 3+2 axis control machining method that uses the voxel model to perform the rough machining process with high efficiency, and the simultaneous five-axis control machining method that uses a complete convex shape model for rough machining. We confirm the results with a computer simulation and actual machining experiments.

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.

Process planning based on cylindrical or conical surfaces for five-axis wire and arc additive manufacturing

2020 ◽  
Vol 26 (8) ◽  
pp. 1405-1420
Author(s):  
Fusheng Dai ◽  
Haiou Zhang ◽  
Runsheng Li
Keyword(s):  
Additive Manufacturing ◽  
Path Planning ◽  
Process Planning ◽  
Flat Surface ◽  
Welding Process ◽  
Planning Method ◽  
Content Type ◽  
Tool Paths ◽  
Conical Surfaces ◽  
Five Axis

Purpose The study aims to fabricate large metal components with overhangs built on cylindrical or conical surfaces with a high dimensional precision. It proposes methods to address the problems of generating tool-paths on cylindrical or conical surfaces simply and precisely, and planning the welding process on these developable surfaces. Design/methodology/approach The paper presents the algorithm of tool-paths planning on conical surfaces using a parametric slicing equation and a spatial mapping method and deduces the algorithm of five-axis transformation by addressing the rotating question of two sequential points. The welding process is investigated with a regression fitting model on a flat surface, and experimented on a conical surface, which can be flattened onto a flat surface. Findings The paper provides slicing and path-mapping expressions for cylindrical and conical surfaces and a curvature-speed-width (CSW) model for wire and arc additive manufacturing to improve the surface appearances. The path-planning method and CSW model can be applied in the five-axis fabrication of the prototype of an underwater thruster. The CSW model has a confidence coefficient of 98.02% and root mean squared error of 0.2777 mm. The reverse measuring of the finished blades shows the residual deformation: an average positive deformation of about 0.5546 mm on one side of the blades and an average negative deformation of about −0.4718 mm on the other side. Research limitations/implications Because of the chosen research approach, the research results may lack generalizability for the fabrication based on arbitrary surfaces. Originality/value This paper presented an integrated slicing, tool-path planning and welding process planning method for five-axis wire and arc additive manufacturing.

Smooth Cutting Operation Strategy for High Finishing Machining

2014 ◽  
Vol 875-877 ◽  
pp. 896-900
Author(s):  
Xiao Fei Bu ◽  
Hu Lin ◽  
Long Chen
Keyword(s):  
Tool Path ◽  
Tool Path Generation ◽  
Machining Process ◽  
Path Generation ◽  
Tool Paths ◽  
Constant Scallop Height ◽  
Simulation And Experiment ◽  
Cutting Operation ◽  
Five Axis ◽  
Finishing Machining

High finishing machining tool path generation methods are usually adopted for five-axis computer numerically controlled machining of sculptured surface parts. The quality of the high finishing machining has an important effect on that of the surface. In this paper, a high finishing machining tool path generation method is introduced to generate an optimal tool path. The initial tool path is firstly created based on the constant scallop height, then the derived tool paths are generated as a kind of the diagonal curve by the initial tool path, and at last, the tool path smoothing algorithm is applied to the generated tool path. This path algorithm can ensure higher level of smooth of the surface been machined. Finally, the results of simulation and experiment of the machining process are given to verify the smooth and applicability of the proposed method.

A Graph-Based Approach for Capturing the Capability Envelope of a Machining Process

2003 ◽  
Vol 125 (2) ◽  
pp. 272-288 ◽  
Author(s):  
Zhengdong Huang ◽  
Derek Yip-Hoi ◽  
Ji Zhou
Keyword(s):  
Process Planning ◽  
Machining Process ◽  
Machining Operations

In this paper, we present a method to determine the capability envelope of a machining process which consists of a sequence of parameterized machining operations. First, operations as well as workpiece in a machining process are represented using a Parametric Feature Relational Graph (P-FRG). Second, the workpiece P-FRG within a process is updated step-by-step by mixing with operation P-FRGs as the operations in the process are successively applied to it. Since alternative setups may exist for an operation, a tree of workpiece P-FRGs can be generated for a process. All the P-FRGs at the leaf nodes of the tree together form the capability envelope of the machining process, that is, the envelope of the parts that can be produced using the process from a given initial workpiece. The parameter mappings, from the parameters of a machining process to the parameters of a part P-FRG in the capability envelope, are also given in this paper. The capability envelope can be applied to the integration of part design and process planning.

Holes Machining Process Optimization with Genetic Algorithm

2011 ◽  
Vol 460-461 ◽  
pp. 117-122 ◽  
Author(s):  
Guang Yu Zhu ◽  
Lian Fang Chen
Keyword(s):  
Genetic Algorithm ◽  
Cutting Tool ◽  
Machining Process ◽  
Processing Route ◽  
Optimal Route ◽  
Optimal Processing ◽  
Global Optimal ◽  
Level Method ◽  
Multi Level ◽  
Changing Times

In this paper, a multi-level method has been adopted to optimize the holes machining process with genetic algorithm (GA). Based on the analyzing of the features of the part with multi-holes, the local optimal processing route for the holes with the same processing feature is obtained with GA, then try to obtain the global optimal route with GA by considering the obtained local optimal route and the holes with different features. That is what the multi-level method means. The optimal route means the minimum moving length of the cutting tool and the minimum changing times of the cutting tool. The experiment is carried out to verify the algorithm and the proposed method, and result indicates that with GA and using the multi-level method the optimal holes machining route can be achieved efficiently.

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