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.

Tool Path Planning of the Micro Cowled Integral Impeller

2011 ◽  
Vol 228-229 ◽  
pp. 708-713
Author(s):  
Zhen Yu Han ◽  
Run Bing Liu ◽  
Hong Ya Fu
Keyword(s):  
Path Planning ◽  
Tool Path ◽  
Complex Structure ◽  
Large Diameter ◽  
Small Dimension ◽  
Numerical Control ◽  
Machining Process ◽  
Processing Route ◽  
Tool Path Planning ◽  
Planning Scheme

The micro crowled integral impeller is one of the key parts of aeroengine. It is difficult to machine for its complex structure and small dimension. In this paper, the tool path planning scheme of micro crowled integral impeller is researched, which lays foundation for the numerical control machining of the part. To begin with, considering the feature of impeller’s structure, a kind of processing route is proposed and the processing regions are divided, which satisfy the demand of accuracy and efficiency. Then, the tool path planning scheme of the impeller is put forward, which is regular and is more suitable for a large-diameter tool to fulfill the machining process. Finally, machining simulation is carried out to prove the feasibility and correctness of the proposed path planning scheme.

Integrated Local and Global Tool Path Planning for Feature-Based Machining

2000 ◽  
Author(s):  
Eric Wang ◽  
Il-Kyu Hwang ◽  
Yong Se Kim
Keyword(s):  
Path Planning ◽  
Tool Path ◽  
Tool Path Generation ◽  
Machining Process ◽  
Path Generation ◽  
Tool Path Planning ◽  
Machining Features ◽  
Tool Paths ◽  
Free Spaces ◽  
Local Tool

Abstract We describe an automatic machining tool path generation method that combines local tool path planning for machining features with global tool path planning. From the solid model and the tolerance specifications of the part, machining features are automatically recognized, and geometry-based precedence relations are obtained between these features. From this information, the machining sequence, tool selections, and machining conditions are determined. Machining tool paths are then generated automatically for each setup, combining local and global tool paths. Local tool paths to machine each feature are generated using successive offsetting operations. Global tool paths between features are generated incrementally by searching the adjacency graph of feature free spaces, which represents the current free space of the part. Feature free spaces are obtained by expanding the machining features through their fictitious faces. The start and end positions for the local tool paths of each feature are selected based on a heuristic method to minimize the cost of each segment of the global tool path. This automatic tool path generation method is currently being developed as part of a comprehensive machining process planning system.

Stochastic Fractal Modeling and Process Planning for Machining Using Two-Dimensional Iterated Function System

2008 ◽  
Vol 392-394 ◽  
pp. 575-579
Author(s):  
Yu Hao Li ◽  
Jing Chun Feng ◽  
Y. Li ◽  
Yu Han Wang
Keyword(s):  
Path Planning ◽  
Tool Path ◽  
Iterated Function System ◽  
Numerical Control ◽  
Function System ◽  
Tool Path Planning ◽  
Ongoing Research ◽  
Iterated Function ◽  
Planning Algorithm ◽  
Path Planning Algorithm

Self-affine and stochastic affine transforms of R2 Iterated Function System (IFS) are investigated in this paper for manufacturing non-continuous objects in nature that exhibit fractal nature. A method for modeling and fabricating fractal bio-shapes using machining is presented. Tool path planning algorithm for numerical control machining is presented for the geometries generated by our fractal generation function. The tool path planning algorithm is implemented on a CNC machine, through executing limited number of iteration. This paper describes part of our ongoing research that attempts to break through the limitation of current CAD/CAM and CNC systems that are oriented to Euclidean geometry objects.

Researches on Burr Formation in Milling Al-Alloy

2010 ◽  
Vol 135 ◽  
pp. 164-169 ◽  
Author(s):  
Ming Chen ◽  
Bin Rong ◽  
Gang Liu
Keyword(s):  
Aluminum Alloy ◽  
Parameter Optimization ◽  
Tool Path ◽  
Burr Formation ◽  
Al Alloy ◽  
Active Process ◽  
Processing Parameter ◽  
Tool Path Planning ◽  
Rough Machining ◽  
Manufacturing Automation

Burr formation is a bottleneck of the production line and deteriorates the automation integrity. To this question, investigations were carried out in this paper on the burr formation in milling aluminum alloy (Al-alloy), in order to enhance productivity and workpiece quality by active process control. Milling burr formation were predicted and minimized for the sake of rough machining and finishing operation, using strategies of tool path planning, processing parameter optimization as well as workpiece rigidity strengthening. The conclusions reached in this paper are useful in practice to realize burr-free Al-alloy milling for manufacturing automation.

scholarly journals Optimisation of Planning Parameters for Machining Blade Electrode Micro-Fillet with Scallop Height Modelling

Micromachines ◽  
2021 ◽  
Vol 12 (3) ◽  
pp. 237
Author(s):  
Yue Liu ◽  
Zhanqiang Liu ◽  
Wentong Cai ◽  
Yukui Cai ◽  
Bing Wang ◽  
...  
Keyword(s):  
Path Planning ◽  
Tilt Angle ◽  
Tool Path ◽  
End Milling ◽  
Tool Path Planning ◽  
Scallop Height ◽  
Aero Engine ◽  
Tool Tilt Angle ◽  
Five Axis ◽  
Height Model

Aero-engine blades are manufactured by electroforming process with electrodes. The blade electrode is usually machined with five-axis micromilling to get required profile roughness. Tool path planning parameters, such as cutting step and tool tilt angle, have a significant effect on the profile roughness of the micro-fillet of blade electrode. In this paper, the scallop height model of blade electrode micro-fillet processed by ball-end milling cutter was proposed. Effects of cutting step and tool tilt angle the machined micro-fillet profile roughness were predicted with the proposed scallop height model. The cutting step and tool tilt angle were then optimised to ensure the contour precision of the micro-fillet shape requirement. Finally, the tool path planning was generated and the machining strategy was validated through milling experiments. It was also found that the profile roughness was deteriorated due to size effect when the cutting step decreased to a certain value.

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