Multipoint 5-Axis Machining of Curved Surfaces

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The Canadian Tool, Die and Mold making industry is known for its precision and accuracy. In 2002 the Canadian market for tool, dies and molds was around $1.2 billion (Statistics Canada). It dropped by 40+% in the recent recession. The outlook for the market has changed in the recent years and it is on a growth trend. The growth is slated to continue with the increased use of Computer Numerically Controlled Machines in novel ways that reduce production cost and increase productivity. The proposed research program focuses on machining of curved surface typically found in tool, die and molds using 5-axis CNC machines. The work on Multi-Point Machining (MPM), Flank Milling and simulation of machined surfaces have received great attention in academic circles and have lead to the development of commercial software for 5-axis machining of impellers. The current proposal visits the challenges in Multi-Point Machining. The main challenge in the research program stem from the mathematical complexity. A sample methodology used to address the issue is given below, although other technique may evolve from the research program. 1) Simplify the definition of the surface by converting it into a series of adjoining triangles. 2) Drop the tool onto the surface and identify a contact point and a pseudo insert axis. 3) Rotate the tool about the tool axis until a second point of contact is found. 4) Identify the triangles where the contact points lie and slides the tool along the common edge until a third point of contact is found. 5) Develop the above steps for bi-parametric curved surfaces. Work has already started along the sample strategy outlined above. The preliminary investigation of the first three steps has been successful. The steps outlined above will be pursued to completion under this proposal. The success of the strategy will further the goal of moving the advantages of the Multi-Point Machining research program to a level where it can be used in industry effectively.