Papers by Keyword: Freeform Surface

Abstract: The use of freeform (sculptured) surfaces in the product design process is accelerating at an exponential rate driven by functional as well as esthetics demands. CAD/CAM software is a must in their design are relatively well-covered, issues still remain when it comes to the actual manufacture of freeform surfaces. The major issues are related to the chosen feed rate, toolpaths and step over that would assure the required surface quality, the minimization of the total machining time, etc. This research presents an experimental study to define the effects of machining’s parameters (including: feed rate; toolpath and step over) for CNC 3-axis ball end milling process. The result shows a model for cutting is formulated and incorporated into the parameters of machining that is compatible with all CAD/CAM systems. This result can be used to choose parameters of optimum including federate, toolpath and step over when machining of other freeform surfaces. Keywords: Freeform surface; tool path; ball end milling

Abstract: The article deals with comparison and evaluation of the milling strategies that are available in CAM systems and are used to produce components with freeform surfaces. For the purpose of the experiment, sample with freeform features was designed to employ different milling strategies when 3 axis machining. Evaluation of the milling strategies was carried out by surface roughness measurement, comparison of the actual machining time with a simulation time as well as visual control of the sample surface with a surface obtained in simulation. Acquired research results can be utilized within production process of tools with sculptured surfaces, such as tools for metal sheet forming, dies, molds for plastics and many others.

Abstract: This study describes the non-rotationally symmetric diamond turning (XZC turning) for producing large-size precision freeform mirror. This is a high speed machining method as compared with the traditional XYZ diamond milling or fly-cutting. Moreover, the application of this method is a key factor in the development of the ultra-precision light-weight freeform mirror for outer space use. This report introduces these cutting-edge approaches.

Abstract: This paper studies the development of cutting strategy in the fabrication of freeform surface in ultra-precision raster milling (UPRM). The tasks of developing cutting strategy in freeform machining involve in the selection of cutting parameters and the planning of tool paths. An integrated system is built in this study to develop the cutting strategy, automatically generate NC program, simulate the tool paths and machining process, as well as make predictions for the machining time and the surface quality of the raster milled freeform surface. Experiment is conducted to verify the developed system and the experimental results show that the system is applicable for the machining of freeform surface in UPRM. This study therefore contributes to avoiding the need to conduct expensive and time consuming trial cutting tests to ensure the product quality in the freeform machining.