Using rotary contact method for 5-axis convex sculptured surfaces machining

The 5-axis tool positioning strategy named rotary contact method (RCM) for sculptured surfaces machining has been developed in our previous paper (Wengang Fan et al., J Manuf Sci E-T ASME 134(2):021004.1-021004.6, 2012). The RCM finds the optimal tool positions by rotating the tool backward based on the offset surface instead of the design surface, and can generate big machined strip width without gouging. However, the RCM only deals with concave sculptured surfaces machining well at present, and the special property of convex sculptured surfaces machining has not been fully exploited. To resolve this problem, the general convex sculptured surfaces machining using the RCM is implemented in this paper. Firstly, the tool position error distribution for different tool feed directions is deeply investigated. It is concluded that the best tool feed direction is collinear with the maximum direction of curvature, which is completely opposite to the case for concave sculptured surfaces machining. Then the relationship between the key parameters in the RCM and the tool position error distribution as well as the tool path generation is totally discussed. Finally, machining simulation and cutting experiment of a convex sculptured surface example are performed. The results show that the RCM can apparently raise the efficiency of manufacturing process by contrast with the algorithm in the software UG for convex sculptured surfaces machining.

[1]  Sanjeev Bedi,et al.  Intersection approach to multi-point machining of sculptured surfaces , 1998, Comput. Aided Geom. Des..

[2]  Sanjeev Bedi,et al.  Five-axis milling of spherical surfaces , 1996 .

[3]  John C. J. Chiou,et al.  Accurate tool position for five-axis ruled surface machining by swept envelope approach , 2004, Comput. Aided Des..

[4]  Chih-Hsing Chu,et al.  Tool path planning for five-axis flank milling with developable surface approximation , 2006 .

[5]  Yuan-Shin Lee,et al.  Admissible tool orientation control of gouging avoidance for 5-axis complex surface machining , 1997, Comput. Aided Des..

[6]  Sanjeev Bedi,et al.  Tool path planning for five-axis machining using the principal axis method , 1997 .

[7]  Xin Wang,et al.  Tool-path generation for machining sculptured surface , 1995 .

[8]  Paul J. Gray,et al.  Arc-intersect method for 5-axis tool positioning , 2005, Comput. Aided Des..

[9]  Hong Jiang,et al.  Rotary Contact Method for 5-Axis Tool Positioning , 2012 .

[10]  Xin Wang,et al.  Gouge detection and tool position modification for five-axis NC machining of sculptured surfaces , 1995 .

[11]  Sanjeev Bedi,et al.  Multi-point tool positioning strategy for 5-axis mashining of sculptured surfaces , 2000, Comput. Aided Geom. Des..

[12]  Jian Liu,et al.  Optimization of tool positions locally based on the BCELTP for 5-axis machining of free-form surfaces , 2010, Comput. Aided Des..

[13]  Yuan-Shin Lee,et al.  Non-isoparametric tool path planning by machining strip evaluation for 5-axis sculptured surface machining , 1998, Comput. Aided Des..

[14]  Sanjeev Bedi,et al.  PII: S0890-6955(99)00058-9 , 1999 .

[15]  G. W. Vickers,et al.  Ball-Mills Versus End-Mills for Curved Surface Machining , 1989 .

[16]  Sanjeev Bedi,et al.  Implementation of the principal-axis method for machining of complex surfaces , 1996 .

[17]  Paul J. Gray,et al.  Rolling ball method for 5-axis surface machining , 2003, Comput. Aided Des..

[18]  Paul J. Gray,et al.  Arc-intersect method for 31212-axis tool paths on a 5-axis machine , 2007 .

[19]  B. Ravani,et al.  Cylindrical milling of ruled surfaces , 2008 .

[20]  Jian Liu,et al.  Second order approximation of tool envelope surface for 5-axis machining with single point contact , 2008, Comput. Aided Des..

[21]  S. K. Ghosh,et al.  Curvature catering-a new approach in manufacture of sculptured surfaces (part 1. theorem) , 1993 .