A cutter path generation strategy for helical surface machining of screw rotor

In this article, the disk mill cutter path generation strategy for the machining of complex helical surface via a currently developed minimal orientation-distance algorithm based on spatial discretization method is studied. The strategy proposed here is, first, to establish the helical surface and cutting surface in the unique coordinate system. Then, the two surfaces are divided into a series of parts by n equidistant planes, and the minimal orientation-distance algorithm is used to determine all the cutter locations. Finally, on the basis of Archimedes helical interpolation, cutter path is generated within the specified tolerance limit. The effectiveness of the proposed strategy is confirmed numerically and experimentally by a case of virtual cutting test in VERICUT software and actual machining. This strategy can be applied to a broad range of helical surface machining.

Isoscallop of Self-Adaptive Tool Orientation with Toroidal Cutter under Optimum Orientation of MCPs

End-milling of free-form surfaces on 5-sxis NC tools is a complex problem which has been studied by a large number of research scientists. When end-milling non-convex surfaces, there is a risk of interference between the tool and the surface. This paper presents a new approach to generate gouging-free tool path for constant scallop-height machining using 5-axis toroidal milling. Based on second-order approximations of the machined strip width, we present locally optimal cutting positions for cutting directions. The largest machined strip width of iso-scallop and the corresponding gouging-avoidance tool orientation are calculated. In the cutter path generation procedures, the master cutter paths have been chosen from the minimum curvature loci of the surface. The tool path generated by this method are also compared with that of the long edge of surface as the MCP, the results of simulation show that the method can yield a reduction in line segments of tool path . Velocity curve and acceleration curve are smoother.

Interactive Haptic Refinement of a Five-Axis Finishing Cut

This paper describes the design of a haptic system that allows the interactive modification of cutter orientation during five-axis finishing cuts with the aim of improving the surface finish quality and collision avoidance strategies. The system supports two haptic models that provide three degree of freedom (DOF) force feedback and 6DOF posture sensing. Details of five key functions of the system are given: (1) a rendering conversion that uses 3DOF (instead of five) force feedback haptic representation, (2) an efficient force feedback design that allows accurate results to be obtained from the user’s manipulation, (3) a fast collision detection scheme that achieves real-time feedback, (4) use of active haptic guidance to assist cutter-path generation, and (5) a design that supports both ball-end and flat-end tools with partial optimization.

Automatic Toolpath Generation for Multi-Axis Surface Machining in a Hybrid Manufacturing System

In a multi-axis hybrid manufacturing system, it is necessary to utilize a machining process to improve surface accuracy and guarantee overall geometry after the deposition process. Due to the complexity of the multi-axis system, it is necessary to find proper orientations of cutting tools for the CNC machine to finish surface machining. This paper presents an algorithm to find collision-free surface machining toolpath for a given workpiece. The concept of the 2-D visibility map and its properties are discussed. The algorithm to compute the 2-D visibility map is presented. With the help of the 2-D visibility map, an optimal a collision free tool approaching direction can be easily decided. Also the type of the surface machining toolpath for different types of surfaces is decided based on topological information and the machining toolpath (CL data for milling tool). The developed planning scheme has been tested via machine simulations and has shown that it can be effectively applied to cutter-path generation for multi-axis surface machining.