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TECHNICAL BRIEFS

Optimal CNC Plunger Selection and Toolpoint Generation for Roughing Sculptured Surfaces Cavity

[+] Author and Article Information
Tawfik T. El-Midany, Ahmed Elkeran

Production Engineering and Mechanical Design Department, Mansoura University, Mansoura, Egypt

Hamdy Tawfik1

Technology Development Branch, Specialized Studies Academy, Workers’ University, 25816-Mit Mahmoud, Mansoura, Egypttawfikhtm@gawab.com

1

Corresponding author.

J. Manuf. Sci. Eng 128(4), 1025-1029 (Mar 28, 2006) (5 pages) doi:10.1115/1.2280873 History: Received May 27, 2005; Revised March 28, 2006

Plunge milling is among the most effective methods of deep core/cavity shaped rough machining techniques. Previous research work had not considered the optimization of plunger selection and toolpoint path. In this paper a new method is proposed (overlapped circles filling (Ocfill)) for optimizing the selection of plungers and toolpoint path generation. The proposed method is used to fill 2D area with a number of overlapped circles. The 2D area is expressed as the feature that being cutting with plunge milling and the circles are plunging holes. The Ocfill method has been implemented in Visual C++. The Ocfill is applied to many examples. The results show that, Ocfill saves rough machining time by significant value up to 28%. This value depends on the shape and complexity of the workpiece that is being cut.

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Copyright © 2006 by American Society of Mechanical Engineers
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Figures

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Figure 3

Generation of Ocfill grid

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Figure 4

Tool radius, overlapped value, and uncut and overcut areas

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Figure 5

Single layer cutting

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Figure 6

Applying of GFLS to optimize traveling toolpoint path length

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Figure 2

Resolution of Ocfill grid

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Figure 1

Calculating the enclosed square and circle

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Figure 11

Ocfill toolpoint path for example (II)

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Figure 12

Photo of final product for example (II)

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Figure 13

Plunge-mill toolpoint path for example (II)

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Figure 7

Rendering of CAD drawing for example (I)

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Figure 8

Ocfill toolpoint path for example (I)

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Figure 9

Photo of final product

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Figure 10

Rendering of CAD drawing for example (II)

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