Dynamic In-Process Stock Based Tool Path Generation for High Surface Finish Rough Machining

Abstract:

This paper presents a new tool path generation strategy for rough machining based on the dynamic in-process stock model of the workpiece. Compared to conventional roughing method, the new tool paths result in a better surface finish but consume the same machining time. The cutter locations in the tool path are determined by removing the peak portion of the residual materials on the stock. The geometric information of remaining stocks is updated dynamically in the in-process model once each cutting pass is completed. The overall machining time is no longer than the conventional method since no additional tool paths are added. The proposed method was implemented in Catia and has been validated by simulation and cutting tests with flat end and ball nose cutters on a 3-axis CNC milling machine.

• Periodical: Key Engineering Materials (Volume 567)
• Pages: 59-65
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.567.59
• Online since: July 2013
• Authors: Song Lin Ding, John Mo, Daniel Yang
• Keywords: In-Process Stock, Rough Machining, Surface Finish, Tool Path

References

[1] C.K. Toh. Cutter path strategies in high speed rough milling of hardened steel. Materials and Design, 27(2006)107 – 114.

DOI: 10.1016/j.matdes.2004.09.021

[2] L.C. Chuang, H.T. Yong, Integrated rough machining methodology for centrifugal impeller manufacturing, International Journal of Advanced Manufacturing Technology, 34(2007)1062 -1071.

DOI: 10.1007/s00170-006-0675-3

[3] B. Lauiwers, P.P. Lefebvre. Five-axis rough milling strategies for complex shaped cavities based on morphing technology. Annals of CIRP, 55(2006)59 -62.

DOI: 10.1016/s0007-8506(07)60366-7

[4] J. Ajay, W.F. Yuen, and Y.S. Lee. Greedy tool heuristic approach to rough milling of complex shaped pockets. IIE Transaction, 35(2003)953–963.

DOI: 10.1080/07408170309342347

[5] S. Tao and K. -L. Ting, Unified rough cutting tool path generation for sculptured surface machining. International Journal of Production Research, 39(2001) 2973-2989.

DOI: 10.1080/00207540110052553

[6] S. H. F. Chuang and I. Z. Wang, Multipatched B-Spline Surfaces and Automatic Rough Cut Path Generation, International Journal of Advanced Manufacturing Technology, 16(2000)100–106.

DOI: 10.1007/s001700050014

[7] Vafaeesefat and H. A. E. Maraghy, Rough pocketing of multi-sculptured surface cavities, Proc Instn Mech Engrs Part B, 215(2001)745 – 753.

DOI: 10.1243/0954405011518638

[8] Y.S. Lee and Bahattin Koc, Ellipse-offset approach and inclined zig-zag method for multi-axis roughing of ruled surface pockets, Computer-Aided Design, 30(1998)957–971.

DOI: 10.1016/s0010-4485(98)00051-7

[9] D.M. Tsay, C. W Chen, G. Student, Improving rough cutting efficiency for machining of impellers, Proceedings of the ASME Turbo Expo, 4(2004)837-844.

DOI: 10.1115/gt2004-54025

[10] P. Pal, Remaining stock computation for 3D-machining in parametric regime, Journal of Manufacturing Science And Engineering, Transactions of the ASME, 127 (2005) 801-809.

DOI: 10.1115/1.2034510

[11] S. Ding, M. A. Manan, A. N. Poo , D.C. H. Yang and Z. Han Adaptive iso-planar tool path generation for machining of free-form surfaces , Computer Aided Design, 35 (2003)141-153.

DOI: 10.1016/s0010-4485(02)00048-9

[12] K. Suresh, D.C.H. Yang, Constant scallop-height machining of free-form surfaces, ASME Journal of Engineering for Industry. 116(1994)253-259.

DOI: 10.1115/1.2901938

[13] J.S. Chen, Y.K. Huang and M.S. Chen. A study of the surface scallop generating mechanism in the ball-end milling process. International Journal of Machine Tools & Manufacture, 45(2005) 1077–1084.

DOI: 10.1016/j.ijmachtools.2004.11.019