In milling around sharp corners, residual materials are left at sharp corners when the stepover is extremely long in the contour-parallel tool path. Milling force at the sharp corner rises momentarily due to the incre...In milling around sharp corners, residual materials are left at sharp corners when the stepover is extremely long in the contour-parallel tool path. Milling force at the sharp corner rises momentarily due to the increase of the cutter contact length, thus shortening the tool life and leading to machine chatter, even cutter breakage. Then a tool path improvement method by inserting biarc transition segments in the contour-parallel tool path is proposed for milling the pocket. Using the method, the cutter moves along the biarc transition tool path. And the corner material is removed. The improved tool path is continuous for clearing residual materials at the sharp corner. Finally, the machining experiment validates the proposed method.展开更多
The methodology of 5-axis cutter selection to avert collision for free-form surface machining by flat-end cutters is presented. The combination of different cutters is adopt aiming at short machining time and high pre...The methodology of 5-axis cutter selection to avert collision for free-form surface machining by flat-end cutters is presented. The combination of different cutters is adopt aiming at short machining time and high precision. The optimal small cutter is determined based on the geometric information of the points where a cutter most probably collide with the machined surface. Several larger cutters are selected to machine the surface in order to find the interference-free area. The difference of machining time for this area between the optimal small cutter and the large cutters is calculated. The functional relationship between the machining time and the radius of a cutter is established, by which the optimal number of cutters is obtained. The combination of cutters, which possesses the minimum overall machining time, is selected as the optimal cutter sizes. A case study has demonstrated the validity of the proposed methodology and algorithms.展开更多
文摘In milling around sharp corners, residual materials are left at sharp corners when the stepover is extremely long in the contour-parallel tool path. Milling force at the sharp corner rises momentarily due to the increase of the cutter contact length, thus shortening the tool life and leading to machine chatter, even cutter breakage. Then a tool path improvement method by inserting biarc transition segments in the contour-parallel tool path is proposed for milling the pocket. Using the method, the cutter moves along the biarc transition tool path. And the corner material is removed. The improved tool path is continuous for clearing residual materials at the sharp corner. Finally, the machining experiment validates the proposed method.
基金Funded by the Doctorate Degree Program Foundation of the Ministry of Education (No. 2000061120)
文摘The methodology of 5-axis cutter selection to avert collision for free-form surface machining by flat-end cutters is presented. The combination of different cutters is adopt aiming at short machining time and high precision. The optimal small cutter is determined based on the geometric information of the points where a cutter most probably collide with the machined surface. Several larger cutters are selected to machine the surface in order to find the interference-free area. The difference of machining time for this area between the optimal small cutter and the large cutters is calculated. The functional relationship between the machining time and the radius of a cutter is established, by which the optimal number of cutters is obtained. The combination of cutters, which possesses the minimum overall machining time, is selected as the optimal cutter sizes. A case study has demonstrated the validity of the proposed methodology and algorithms.
