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Research Papers

Synchronous Adjustment of Milling Tool Path Based on the Relative Deviation

[+] Author and Article Information
Xiao-Jin Wan, Lin Hua

Hubei Key Laboratory of Advanced Technology of Automotive Parts, School of Automotive Engineering,  Wuhan University of Technology, Wuhan 430070, P.R. China

Cai-Hua Xiong

State Key Laboratory of Digital Manufacturing Equipment and Technology of China,  Huazhong University of Science and Technology, Wuhan 430074, P.R. China

J. Manuf. Sci. Eng 133(5), 051010 (Oct 17, 2011) (12 pages) doi:10.1115/1.4004201 History: Received March 17, 2010; Revised April 26, 2011; Published October 17, 2011; Online October 17, 2011

In machining process, machining accuracy of part mainly depends on the position and orientation of the cutting tool with respect to the workpiece which is influenced by errors of machine tools and cutter-workpiece-fixture system. A systematic modeling method is presented to integrate the two types of error sources into the deviation of the cutting tool relative to the workpiece which determines the accuracy of the machining system. For the purpose of minimizing the machining error, an adjustment strategy of tool path is proposed on the basis of the generation principle of the cutter location source file (CLSF) in modern computer aided manufacturing (CAM) system by means of the prediction deviation, namely, the deviation of the cutting tool relative to the workpiece in computer numerical control (CNC) machining operation. The resulting errors are introduced as adjustment values to adjust the nominal tool path points from cutter location source file from commercial CAM system prior to machining. Finally, this paper demonstrates the effectiveness of the prediction model and the adjustment technique by two study cases.

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Copyright © 2011 by American Society of Mechanical Engineers
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Figures

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Figure 1

Analysis of source errors in a generic machining system

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Figure 2

Comparison results of the unmodified tool path with the modified tool path from CAM system. (a) Cutting simulation in CAM, (b) the unmodified tool path, (c) the modified tool path, (d) surface texture from the unmodified tool path, and (e) surface texture from the modified tool path

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Figure 4

Comparison of profile between the modification and no modification, (a) cutting path 1, (b) local amplification from (a), and (c) cutting path 2

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Figure 5

Comparison of tool paths between modified and nominal CLSF. (a) Tool path from cam and (b) top view from (a).

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Figure 6

Comparison of surface residual error between adjustment tool path and nominal tool path (cam ). (a) Surface error from nominal tool path and (b) surface error from adjusted tool path.

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Figure 7

Machining test experiment.

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Figure 8

Comparison of measured profiles between adjusted tool path and nominal tool path (L1). (a) Profiles curves measured by laser displacement sensor and (b) profiles curves measured by a Taylor–Hobson contour device.

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Figure 9

Comparison of measured profiles between adjusted tool path and nominal tool path (L2). (a) Profiles curves measured by laser displacement sensor and (b) profiles curves measured by a Taylor–Hobson contour device.

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Figure 10

Comparison of measured profiles between adjusted tool path and nominal tool path (L3). (a) Profiles curves measured by laser displacement sensor and (b) profiles curves measured by a Taylor–Hobson contour device.

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Figure 11

Comparison of measured profiles between adjusted tool path and nominal tool path (L4). (a) Profiles curves measured by laser displacement sensor and (b) profiles curves measured by a Taylor–Hobson contour device.

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