State-of-the-Art in Geometric Modeling for Virtual Machining

2012 ◽  
Author(s):  
Eyyup Aras ◽  
Derek Yip-Hoi
Keyword(s):  
Computer Technology ◽  
Process Modeling ◽  
Geometric Modeling ◽  
Tool Path ◽  
State Of The Art ◽  
Machining Process ◽  
Work Piece ◽  
Virtual Machining ◽  
Swept Volumes ◽  
Process Work

Advances in computer technology have made possible the integration of complex geometric and process modeling capabilities for use in engineering design and process planning. This is evident in the area of machining where it is now possible to integrate the physics of the machining process with changes that are taking place to the geometry of a work piece during the execution of complex operations. This capability is referred to as Virtual Machining (VM). Geometric modeling capabilities include the ability to generate complex swept volumes created during execution of tool path moves, to subtract these from a dynamically changing in-process work piece model, and to extract the instantaneous cutter/workpiece engagement as the tool moves in the feed direction. Process modeling includes the use of this engagement geometry to calculate cutting forces, deflection of structures, vibrations and to use these in process optimization. This paper reviews advances in the first part of this tandem, the geometric modeling methods and techniques that make Virtual Machining possible. It further highlights important directions that can be taken to further advances in this field.

scholarly journals Emergent Structure Detection for Multi-Axis Machining

2010 ◽  
Author(s):  
Joseph E. Petrzelka ◽  
Matthew C. Frank
Keyword(s):  
Path Planning ◽  
Tool Path ◽  
Medial Axis ◽  
Transient State ◽  
Machining Process ◽  
Work Piece ◽  
Catastrophic Failure ◽  
Tool Path Planning ◽  
Rough Machining ◽  
Emergent Structure

This paper examines the phenomenon of emergent structures that occur in the transient stock material during multi-axis rough machining from a plurality of fixed orientations. Taking the form of thin webs and strings, emergent structures are stock material conditions that can lead to catastrophic failure during machining, even when tool path verification is successful. We begin by discussing the motivation for use of fixed orientations in multi-axis machining using multiple automated setups via rotary axes, which enables fast processing and ‘first part correct’ machining. Next, we demonstrate how unintended emergent structures occur in this paradigm of machining and can lead to catastrophic failure of the tool or work piece. Our original work focuses on the problem of geometric detection of these structures during process planning and prior to tool path planning, to the end of altogether avoiding emergent structure formation. To quickly simulate the machining process, we present an object-space method for determining the transient state of stock material based on the inverse tool offset. To identify emergent structures within this transient stock state, we propose a metric based on the medial axis transformation. Finally, we present our implementation of these methods and demonstrate realtime computation appropriate for an optimization scheme to eliminate emergent structures. Our methods provide consistent and logical results, as demonstrated with several freeform component examples. This work enables the development of robust algorithms for autonomous tool path planning and machining in multi-axis environments.

Computer-Aided Manufacturing (CAM) Software Development for Laser Machining

2013 ◽  
Author(s):  
Abdolreza Bayesteh ◽  
Farid Ahmad ◽  
Martin B. G. Jun
Keyword(s):  
Laser Ablation ◽  
Tool Path ◽  
Laser Energy ◽  
Machining Process ◽  
Work Piece ◽  
Software System ◽  
Computer Aided Manufacturing ◽  
Computer Aided ◽  
Tool Trajectory ◽  
Cam Software

A novel computer-aided manufacturing (CAM) software system is proposed for laser ablation machining process. The algorithms and prototype software system is designed to offer efficient optimization of tool path for controlled delivery of laser energy into work-piece. The software simplifies part program creation and maintains constant velocity of the sample stage for each segment of a complex tool trajectory. These features enable efficient deposition of laser energy into the work piece and therefore, reduction in heat-affected zone is expected in laser ablation based micromachining. The reported software provides fast modification of tool path, automatic and efficient sequencing of path elements in a complicated tool trajectory, location of reference point and automatic fixing of geometrical errors in imported drawing exchange files (DXF) or DWG format files.

The Research of the Logarithmic Spiral Axis and NC Machining

2010 ◽  
Vol 135 ◽  
pp. 102-106 ◽  
Author(s):  
Ning Luo ◽  
You Yi Zheng ◽  
Guo Tai Han ◽  
Ke Jiang
Keyword(s):  
Geometric Modeling ◽  
Tool Path ◽  
Logarithmic Spiral ◽  
Nc Machining ◽  
Cnc Machining ◽  
Machining Process ◽  
Machining Center ◽  
High Fatigue ◽  
A New Technique ◽  
Cnc Machining Center

The characteristics of surface connection include high fatigue strength, high centering ability, easy dismantling and long life. According to these characteristics and based on the analysis of logarithmic spiral equation, the article explores a new technique of the matched logarithmic spiral profile connection to facilitate efficiently by formulating the machining process and analysing the part technology to determine the geometric modeling, tool path and simulation of NC machining graph and to inspect the process of Logarithmic spiral axes CNC Machining Center and CMM.

A Feature-Based Approach for Cutter/Workpiece Engagement Calculation in 2-1/2D End Milling

2006 ◽  
Author(s):  
Jue Wang ◽  
Derek Yip-Hoi
Keyword(s):  
Process Modeling ◽  
Cutting Forces ◽  
End Milling ◽  
Process Models ◽  
Machining Process ◽  
Geometric Invariant ◽  
Machining Features ◽  
Virtual Machining ◽  
Feature Based ◽  
Intersection Geometry

Machining process modeling requires cutter/workpiece engagement geometry in order to predict cutting forces. The calculation of these engagements is challenging due to the complicated and changing intersection geometry that occurs between the cutter and the in-process workpiece. Solid modelers can be used to perform these calculations by executing intersection operations between cutter and workpiece surfaces at successive cutter locations. These operations utilize parametric surface/surface intersection (SSI) algorithms. For the large number of engagements that can occur in machining a complicated workpiece this can be a time-consuming and sometimes unreliable process. In this paper, in-process machining features are introduced into machining process modeling for 2 1/2 D end milling, and a feature based approach is presented for addressing the computational complexity and robustness issues in the cutter/workpiece engagement calculations. Geometric Invariant (giF) and Form Invariant Machining Features (fiF) are modeled to help represent engagement conditions analytically. Volume decomposition and composition algorithms are described that extract these two types of machining features from the removal volumes generated at each tool pass. Cutter/workpiece engagements can be analytically extracted from giFs and fiFs without applying repetitive SSI operations. This paper presents one part of ongoing collaborative research into developing Virtual Machining Systems. The engagement conditions that are found are inputs to machining process models that identify cutting forces, predict stability and that optimize the process.

Solid Modeling of In-Process Workpiece Geometry for Hole Milling

2012 ◽  
Author(s):  
Jue Wang ◽  
Derek Yip-Hoi
Keyword(s):  
Cutting Forces ◽  
Tool Path ◽  
Solid Modeling ◽  
Solid Model ◽  
Virtual Machining ◽  
Solid Models ◽  
Milling Operation ◽  
Swept Volumes ◽  
Swept Volume ◽  
Physics Based Simulation

Capturing the in-process workpiece geometry generated during machining is an important part of tool path verification and increasingly the physics-based simulation of cutting forces used in Virtual Machining. Swept volume generation is a key supporting methodology that is necessary for generating these in-process states. Hole milling is representative of one class of milling operation where the swept volume is continuously intersecting. Due to this it is impossible to decompose the tool path into non-intersecting regions which is typically the approach used in solid model based swept volume generation. In this paper an approach to generating NURBS based solid models for self-intersecting swept volumes generated during hole milling is presented. NURB surfaces are generated that compactly represent the surfaces of the swept volume. This utilizes the geometry of the helical curve as opposed to a linearly interpolated tool path that is used for more generic approaches to generating swept volumes. Examples applying the approach to various types of cutter geometries used in milling are presented.

Development of an Integrated System of Geometric Modeling and Machining Simulation of End Mill

2011 ◽  
Vol 120 ◽  
pp. 74-80
Author(s):  
Rong Li ◽  
Xue Feng Chen ◽  
Guo Fu Ding ◽  
Jian Jun Liu ◽  
Xiao Bo Jin
Keyword(s):  
Simulation Model ◽  
Geometric Modeling ◽  
Tool Path ◽  
Modular Design ◽  
Parametric Design ◽  
Integrated System ◽  
Digital Manufacturing ◽  
Machining Simulation ◽  
Virtual Machining ◽  
End Mills

An integrated system of geometric modeling and machining simulation of end mills is presented for supporting end mill’s cutting analysis, structural optimization and digital manufacturing. In order to obtain accurate structural models, the main elements and detail features of end mills are modeled precisely, based on modular design and parametric design methodology. Through integrates 2D tool path and 3D virtual machining simulation seamlessly, a comprehensive simulation platform is constructed. To ensure the accuracy of manufacturing simulation model, the machining simulation model is compared to ideal design model. The results verify the correctness and rationality of the geometric modeling and machining simulation. NC codes generated by machining simulation can be output to tool grinder, supporting digital manufacturing of end mills.

Research on NC Machining and Accurate Modeling of Curve Bevel Gear

2014 ◽  
Vol 686 ◽  
pp. 497-502
Author(s):  
Zhi Gang Liu
Keyword(s):  
Machine Tool ◽  
Tool Path ◽  
Nc Machining ◽  
Bevel Gear ◽  
Machining Process ◽  
Work Piece ◽  
Cnc Milling ◽  
Processing Parameter ◽  
Nc Simulation ◽  
Tool Motion

This paper first analyzes the NC simulation and NC machining process of curve bevel gear, and provides the basic equations and the formulae in detail based on the CNC 3 axis linkage machine tool cutting. Directly to takes the rotation angle of the work gear as machine tool motion parameters, the axes of other motion work piece express the gear angle function. Finally, according to the characteristics of curve bevel gear, we select reasonable processing technology, setting processing parameter of curve bevel gear, then test the tool path simulation and program processing, and finally the use of CNC milling machine with three linkage process curve bevel gear.

Development of Machining Method for Micromold

2010 ◽  
Vol 154-155 ◽  
pp. 310-313
Author(s):  
Xue Feng Bi ◽  
Jin Sheng Wang ◽  
Jia Shun Shi ◽  
Ya Dong Gong
Keyword(s):  
Tool Path ◽  
Simulation Software ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Simulation ◽  
Post Process ◽  
Micro Parts ◽  
G Code ◽  
Micro Machine ◽  
3D Software

Micromold manufacturing technology is very important for the mass production of micro parts. In this paper, modeling of micromold is established in 3D software firstly. The 3D modeling is input into machining simulation software Master CAM to simulate machining process. The machining parameters and cutting tool path are optimized in machining simulation. Machining G code of micromold obtained from post-process program of Master CAM is input into HMI system of Micro Machine Tool (MMT), and hence the micromold will be machined precisely in MMT.

Effect of process parameters on formability in two-point incremental forming-machining of planar and twisted AA5083 blades

2022 ◽  
pp. 095440542110697
Author(s):  
Hossein Ghorbani-Menghari ◽  
Mehrdad Azadipour ◽  
Mehran Ghasempour-Mouziraji ◽  
Young Hoon Moon ◽  
Ji Hoon Kim
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Dimensional Accuracy ◽  
Numerical Control ◽  
Machining Process ◽  
Curved Surface ◽  
Forming Process ◽  
Forming Temperature ◽  
Feature Based ◽  
Tool Diameter

The deformation machining process (DMP) involves machining and incremental forming of thin structures. It can be applied for manufacturing products such as curved-surface blades without using 5-axis computerised numerical control machines. This work presents the effect of tool diameter and forming temperature on spring-back and dimensional accuracy of a simple fabricated part. The results of the first phase of the study are utilised to design the fabrication process of a curved surface blade. A feature-based algorithm is used to design the tool path for the forming process. The dimensional accuracy of the final product is improved through warm forming, two-point incremental forming, and extension of the bending zone to the outside of the product edges. The results show that DMP can be used to fabricate complex curved-surface workpieces with acceptable dimensional accuracy.

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