Papers by Keyword: Tool Path

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Authors: Yu Kui Wang, Zhao Qi Zeng, Zhen Long Wang, Xiao Long He
Abstract: This paper proposed a removal analysis and a contouring strategy of accurate micro-WEDM processing for an aerodynamic micro-air journal bearing for micro-gas turbine engine. It is designed based on aerodynamic theory and can be self-acting by the compressed air pressure. The rotor is stably rotated in a relatively low speed which is below one hundred thousand revolutions per minute, and is much lower than other references. The extended and trimmed tool path is adopted in this paper, and the cusp at the corner of the micro-air journal bearing is obtained by this method which is better than the common arc tool path. The inner and outer diameter of the micro-air journal bearing with a satisfactory shape and good surface quality is 1.068mm and 1.165mm, respectively. The minimum radius at the bottom of wedged-structure is 15.9μm. The kerf of the blanking is 43μm, and the machining discharge gap is 18μm under this machining conditions. The MRR calculated by experimental data is 0.00144mm2/min.
Authors: Hideki Aoyama, Yumiko Suzuki, Noriaki Sano
Abstract: Currently used CAM systems for 5-axis machining can determine tool paths with collision-free tool postures. However, the algorithm implemented in the CAM systems sometimes generates un-optimum tool paths and postures from the viewpoint of machining processes and machine tool operation. This study proposes two methods to determine tool paths and tool postures for 5-axis machining based on the viewpoints of human intuition and minimum cusp height for resolving the problems. A method is developed for inputting the positions and postures of a cutting tool when executing virtual machining. In the execution of virtual machining, a virtual cutting tool can be intuitively moved by a haptic device to determine the desired locations and postures of the cutting tool. By using the system, the tool locations and tool postures to machine complicated shapes with overhang can be easily determined based on the operators intuition. Another method is for determining tool postures for making minimum cusp height by matching the cutting edge of a flat end-mill to the cross-section shape at a point on surfaces to be machined. A basic system to determine the tool postures based on making minimum cusp height was developed. The cusp height on the surfaces generated by the basic system was smaller than the height generated by 3-axis ball-end milling.
Authors: Yurie Okugawa, Naoki Asakawa, Masato Okada
Abstract: While it is important that evaluation of thickness of a product made with press working to evaluate a mold, currently, there is not an appropriate system which can measure thickness of a free curved plate. The study deals with a development of an automatic measurement and evaluation system for thickness of free curved plates, called Orthros. The system measures thickness of a plate with laser displacement gauges and an industrial robot. While the system has been capable for measurement of a relatively simple shaped workpiece, it had collisions between laser-path and workpiece for that of a complicated shape, owing to a geometrical limit about measuring posture of the gauges. In this article, a new method to detect collision and to avoid collision by changing measuring posture on the basis of CAD data is proposed. In the method, not only the geometrical characteristic of the laser-path but also the measuring error characteristic of the gauges depending on the measuring posture are considered and continuous measuring path having change in posture to avoid collision is devised. From the experiment result, it is confirmed that the proposed method has an ability to measure a thickness of a workpiece with complicated shape.
Authors: An Jiang Cai, Fang Rong Ma, Ming Wei Ding, Shi Hong Guo
Abstract: This paper takes dual-spindle turning center as the research object, researching on the key technology of the efficient processing and integration application, the special post processor for dual-spindle turning center was developed based on the IMSPOST, the technical problems of dual-spindle structural system and post processing algorithm for varies of processing modes were solved, the NC processing programs were generated effectively and correctly. Production application showed that: the development of post processor for dual-spindle turning center improves the automation level and quality of NC programming effectively, brings the processing capability of dual-spindle turning center full play, and provides technical support for the manufacturing of complex mechanical products.
Authors: Song Lin Ding, John P.T. Mo, Daniel Yang
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.
Authors: Rusdi Mat Song, Safian Sharif, Ahmad Yasir Md Said, Mohd Tanwyn Mohd Khushairi
Abstract: Selection of the most suitable tool path strategy is very essential during machining especially in computer aided design and manufacture (CAD/CAM) as well as computer numerical control (CNC) machining. Existence of various tool path strategies to be applied on advanced composite materials such as aluminium epoxy required extensive researches in determining the best combination of tool path and cutting parameters for better machinability performance. Pocket milling of aluminium epoxy specimen via CAD/CAM was conducted in this study to investigate the effect of three types of tool path strategies namely Inward Helical, Outward Helical and Back and Forth. Uncoated high speed steel (HSS-Co8) ball end mill was used throughout the experiments. The machining responses that were evaluated include machining time, tool wear rate, tool life and surface finish of the machined pockets. In general, the effect of tool path strategy was highly significant on the machining responses and results showed that Back and Forth strategy offered the best machinability results when compared to the other strategies.
Authors: Amir Rezaei Shahreza, Farshid Dehghani, Mahmood Salimi
Abstract: In present study, spinning process of clad sheets composed of Copper and Stainless steel 304L is investigated experimentally. To achieve the Copper-Steel 304L clad sheet the explosive welding method is used. In order to smooth the surface of clad sheets, a cold roll forming process was carried out. The clad sheets were heat treated to improve the metallurgical bounding and formability. The mechanical properties of copper-steel clad sheet were obtained by experimental measurements. Spinning process was performed on Copper-steel 304L clad sheets with internal layer of copper and external layer of steel. Different experimental tests are carried out to investigate the effects of some influential parameters including the tool path and the tool materials on formability of the clad sheets. Moreover, corresponding numerical simulations were made to verify the experimental values. Finally comparison of thickness strain distribution of a perfect product sample shows a reasonable agreement between numerical and experimental data.
Authors: Xue Guang Li, Guo Quan Shi, Shu Ren Zhang, Lin Sen Song
Abstract: According to the new profiling characteristic of carbide pinion cutter with convex curved rake face, the machining process of convex curved rake face is designed, the special grinding equipment is designed and developed. Tool presetting and detecting equipment is developed by using laser sensor. It can be used to locate the initial location of grinding wheel precisely when convex curved rake face is machining. The tool path for CNC machining is solved. The grinding experiment is done for convex curved rake face of pinion cutter with 21teeth and 5modulus , different process parameters are established. The ideal surface roughness is obtained. The experiment result shows that the grinding equipment and tool presetting equipment are proper for machining requirements of convex curved rake face of pinion cutter.
Authors: Cao Qing Yan, Jun Zhao, Yue En Li, Shi Guo Han
Abstract: Complex surface mold has been widely used in various industries, and high efficiency and high quality can been achieved through high-speed CNC milling processing. Surface roughness including transverse and longitudinal roughness is an important criterion for mold quality. A high-speed milling experiment was performed in mold steel P20 using cemented carbide ball-end mill to investigate the surface roughness. The effects of process parameters on roughness including spindle speed, feed per tooth and radial cutting depth were examined, and an analysis on the mechanism for two kinds of roughness of different tool paths was finished. The experimental results show that the longitudinal roughness improve obviously while the spindle speed and the feed per tooth increase on the high-speed conditions, and the transverse roughness increase significantly when the radial cutting depth increases. And for a smaller roughness value, the tool path should be selected along the direction in which the curvature changes evidently.
Authors: Min Fu, Chun Wei Chen
Abstract: In this paper, on the aim of control the fluctuation of cutting force, five kind of commonly used tool paths which were used to milling curved surface were selected to study the optical cutting tool path of high speed milling al-alloy, the results showed that in order to make the fluctuation of cutting force smallest, the tool path which had the more even line spacing along the Machining surface should be chosen according to the characteristic of the Machining surface. In order to minimize the cutting force, the direction with the biggest surface curvature should be chosen, and the direction with the smallest change rate of the surface curvature should be chosen in order to minimize the fluctuations of cutting force.
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