A three-dimensional configuration-space method for 5-axis tessellated surface machining

Authors:
J. Lu;R. Cheatham;C. G. Jensen;Y. Chen;B. Bowman
Affiliations:
Department of Mechanical Engineering, Brigham Young University, Provo, UT, USA;Department of Mechanical Engineering, Brigham Young University, Provo, UT, USA;Department of Mechanical Engineering, Brigham Young University, Provo, UT, USA;Manufacturing Systems Department, Ford Motor Co., Dearborn, MI, USA;Manufacturing Systems Department, Ford Motor Co., Dearborn, MI, USA
Venue:
International Journal of Computer Integrated Manufacturing
Year:
2008

Citing 2
Cited 2

Practical methods of optimization; (2nd ed.)

Practical methods of optimization; (2nd ed.)
Weights for computing vertex normals from facet normals

Journal of Graphics Tools

Review: Recent development in CNC machining of freeform surfaces: A state-of-the-art review

Computer-Aided Design
Optimal tool orientation control for 5-axis CNC milling with ball-end cutters

Computer Aided Geometric Design

Quantified Score

Hi-index	0.00

Visualization

Abstract

This paper presents a three-dimensional configuration-space (3D C-space) machining method for 5-axis finish machining of tessellated surfaces. To maximize the step-over distance, the curvature matched method (CM2) is used to approximate the cusp height and the step-over distance. A 3D C-space is then built for each cutter contact point (CC point). Every configuration set in this 3D C-space guarantees that the cutter is gouge-free and that the cusp height is less than the machining tolerance. The inclination angle λ by which the cutter is rotated about LY, the yaw angle ω by which the cutter is rotated about LZ and the height δ by which the cutter is lifted along the normal of the surface are three variables used to build the 3D C-space. Next, the optimal cutter orientation is obtained in this corresponding 3D C-space via a special optimization process. The ideal 3D C-space set, the initial 3D C-space set and the objective function of the optimization process are based on machine tool kinematics. Boundary functions are determined by the geometry feature of the 3D C-space. The penalty function method is employed as the optimization method. In this paper, the cutting accuracy is self-guaranteed to be less than the machining tolerance. The cutting speed is set to be as high as possible based on optimal cutter orientation and maximized step-over distance.