A novel iso-scallop tool-path generation for efficient five-axis machining of free-form surfaces
A novel iso-scallop tool-path generation for efficient five-axis machining of free-form surfaces
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DOI：
10.1007/s00170-010-2698-z
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发表时间：
2010-05
期刊：
影响因子：
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通讯作者：
A. Can;Ali Ünüvar
中科院分区：
文献类型：
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作者：
A. Can;Ali Ünüvar
刀具轨迹的生成是有效加工的重要因素。针对自由曲面的五轴加工，提出了一种新的等扇形刀具轨迹生成策略。在所提出的等扇贝法中，对刀具轨迹进行了规划，使相邻两条加工路径之间形成的扇贝高度恒定。沿着刀具轨迹的刀具方向进行了优化，以最大限度地去除材料并避免局部刨削。为此，将有效切割半径调整为表面曲率，然后在扇贝高度恒定的情况下计算侧面步长。提出了一种有效的边步和步长确定的二叉搜索算法。采用曲面曲率分析程序对整个曲面进行了分析，确定了沿进给方向和侧边方向的最小曲率半径。此外，利用曲面曲率分析程序计算出的凹曲率半径，提出了一种可行的平球端刀具选择方法。对所有刀具接触点进行了局部和后刨削分析。结果表明，等扇贝法可将总路径长度减少约22-50%。采用STEP-AP214格式勾画三维自由曲面，采用“b样条曲面与结点”实体定义b样条曲面几何形状。根据所提出的算法，在Borland®Delphi中开发了基于Windows的软件。
Tool-path generation is the most important factor in effective machining. A novel iso-scallop tool-path generation strategy was developed for the efficient five-axis machining of free-form surfaces. In the developed iso-scallop method, the cutter paths were scheduled so that the scallop height formed between two adjacent machining paths was constant. The tool orientations along the tool-paths are optimized to maximize material removal and to avoid local gouging. For this aim, the effective cutter radius was adjusted to the surface curvature and then side step was calculated for a constant scallop height. An effective binary searching algorithm was proposed for side step and step length determination. A surface curvature analysis procedure was applied to the entire surface for determination of the minimum radius of curvatures along the feed and side-step directions. Additionally, a feasible flat-ball-end tool selection method is presented by using the concave radius of curvatures which are calculated by surface curvature analysis procedure. Local and rear gouging was analyzed for all cutter contact points. Based on the results, the iso-scallop method reduced the total path length by about 22–50%. Three-dimensional (3D) free-form surfaces were delineated with the STEP-AP214 format, and the “B-spline-surface-with-knots” entity was used to define the B-spline surface geometry. Windows®-based software written in Borland® Delphi has been developed according to the algorithm presented.