Progressive segmentation for MRR-based feed-rate optimization in CNC machining

Keeping a constant cutting force in CNC machining is very important for obtaining better stability of cutting operation and improving topography, texture and geometry of the machined surface. This paper presents a feed-rate optimization approach based on Material Removal Rate (MRR). Given a tool-path with predefined feed-rates, the geometry of raw material, and the shape of cutter, the histogram of MRR in very fine resolution can be efficiently computed by using a GPU-based geometric modeling kernel. Starting from the evaluation given on the finest histogram of MRR, error-controlled subdivision algorithms are developed to progressively segment the tool-path into user-specified number of sub-regions. Different feed-rates are assigned to different sub-regions so that nearly constant MRR can be achieved while keeping the shape of the given tool-path unchanged. Experimental tests taken on real examples verify the effectiveness of this method.

[1]  Jeffrey G. Hemmett,et al.  Robust Feedrate Selection for 3-Axis NC Machining Using Discrete Models , 2001 .

[2]  Chong Nam Chu,et al.  Cutting force prediction of sculptured surface ball-end milling using Z-map , 2000 .

[3]  C. Hariharan,et al.  Octree-based NC simulation system for optimization of feed rate in milling using instantaneous force model , 2010 .

[4]  Allan D. Spence,et al.  Integrated solid modeler based solutions for machining , 1999, SMA '99.

[5]  Dinesh Manocha,et al.  Fast swept volume approximation of complex polyhedral models , 2003, SM '03.

[6]  Kwangsoo Kim,et al.  Voxel-Based Virtual Multi-Axis Machining , 2000 .

[7]  Alan Sullivan,et al.  High accuracy NC milling simulation using composite adaptively sampled distance fields , 2012, Comput. Aided Des..

[8]  Xun Xu,et al.  Adaptive execution of an NC program with feed rate optimization , 2012 .

[9]  R. S. Naserian,et al.  Static rigid force model for 3-axis ball-end milling of sculptured surfaces , 2007 .

[10]  Dong Wang,et al.  Constant Cutting Force Control for CNC Machining Using Dynamic Characteristic-Based Fuzzy Controller , 2015 .

[11]  Y. Liao,et al.  Prediction of cutting forces in ball-end milling by means of geometric analysis , 2008 .

[12]  Charlie C. L. Wang,et al.  Solid modeling of polyhedral objects by Layered Depth-Normal Images on the GPU , 2010, Comput. Aided Des..

[13]  Mustafa Kurt,et al.  Feedrate optimisation/scheduling on sculptured surface machining: a comprehensive review, applications and future directions , 2011 .

[14]  Stephen C. Veldhuis,et al.  Mechanistic Modeling of Ball End Milling Including Tool Wear , 2006 .