Iso-planar Feed Vector Fields Based Streamline Tool Path Generation for 5-axis Compound Surface Machining with Torus-end Cutters
Iso-planar Feed Vector Fields Based Streamline Tool Path Generation for 5-axis Compound Surface Machining with Torus-end Cutters
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DOI：
10.1115/1.4039653
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发表时间：
2018-07
影响因子：
4
通讯作者：
S. Sun;Yuwen Sun;Jinting Xu;Yuan-Shin Lee
中科院分区：
文献类型：
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作者：
S. Sun;Yuwen Sun;Jinting Xu;Yuan-Shin Lee
提出了一种新的基于参数空间矢量场的流线光顺方法和环面刀具五轴加工复杂复杂曲面的刀位优化技术。等平面刀具轨迹广泛应用于各类曲面的加工，尤其是多面片复合曲面的加工，但复合曲面与一系列平面相交的操作很大程度上依赖于复杂的优化方法。提出了一种新的基于等平面进给矢量场的刀具轨迹光顺方法，该方法不是直接与平面相交，而是基于等平面进给矢量场，用于五轴联动加工。首先以流函数的形式构造参数域中的等平面进给矢量场，该流函数用于生成刀具路径生成的候选流线。然后，提出了一种G1混合算法来混合相邻参数域内的矢量场，以确保跨边界流线的平滑过渡。基于参数域中的平滑流线，路径线及其对应的边尺寸被选为所需的刀具路径。对于高性能加工，还给出了确定刀轴方向的详细计算技术，以确保在每个刀具接触点上，环面端面刀具在没有刨削的情况下与零件表面紧密接触。给出了计算结果和加工实例，验证了所提方法的有效性。
This paper presents a new vector-field-based streamline smoothing method in the parametric space and a tool orientation optimization technique for five-axis machining of complex compound surfaces with torus-end cutters. Iso-planar tool path is widely used in the machining of various types of surfaces, especially for the compound surface with multiple patches, but the operations of intersecting the compound surface with a series of planes have depended considerably on the complicated optimization methods. Instead of intersecting the surface directly with planes, a novel and effective tool path smoothing method is presented, based on the iso-planar feed vector fields, for five-axis milling of a compound surface with torus-end cutters. The iso-planar feed vector field in the parametric domain is first constructed in the form of stream function that is used to generate the candidate streamlines for tool path generation. Then, a G1blending algorithm is proposed to blend the vector fields within the adjacent parametric domains to ensure smooth transition of cross-border streamlines. Based on the smoothened streamlines in the parametric domains, pathlines along with their correspondent side sizes are selected as desirable tool paths. Concerning a high performance machining, detailed computational techniques to determine the tool axis orientation are also presented to ensure, at each cutter contact (CC) point, the torus-end cutter touches the part surface closely without gouging. Both the computational results and machined examples are demonstrated for verification and validation of the proposed methods.