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Research Papers

Rotary Contact Method for 5-Axis Tool Positioning

[+] Author and Article Information
Wengang Fan1

School of Mechanical and Electronic Control Engineering,  Beijing Jiaotong University, Beijing 100044, P.R. Chinawgfan.alan@gmail.com

Xiaochun Wang

School of Mechanical and Electronic Control Engineering,  Beijing Jiaotong University, Beijing 100044, P.R. Chinaxchwang@bjtu.edu.cn

Yonglin Cai

School of Mechanical and Electronic Control Engineering,  Beijing Jiaotong University, Beijing 100044, P.R. Chinaylcai@bjtu.edu.cn

Hong Jiang

School of Mechanical and Electronic Control Engineering,  Beijing Jiaotong University, Beijing 100044, P.R. Chinahjiang1@bjtu.edu.cn

1

Corresponding author.

J. Manuf. Sci. Eng 134(2), 021004 (Apr 04, 2012) (6 pages) doi:10.1115/1.4005792 History: Received May 25, 2010; Revised December 04, 2011; Published March 30, 2012; Online April 04, 2012

In this paper, a new 5-axis tool positioning algorithm called the rotary contact method (RCM) for open concave surface machining using the toroidal cutter is developed. The RCM comes from the reverse thinking of multipoint machining (MPM) method and apparently distinguishes the traditional tool positioning principles, as it determines the optimal tool positions based on the offset surface instead of the design surface. The basic idea of the RCM is to determine the initial tool location first and then rotate the tool for required contact. The RCM can not only guarantee gouge-free tool positions without the additional local gouge checking and correction process but also effectively produce big machined strip width for open form surface machining just like the MPM. Besides, this new method is simple to implement. Machining simulation was performed to verify the validity of the RCM.

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Copyright © 2012 by American Society of Mechanical Engineers
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Figures

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Figure 7

The machining simulation for parameter increment Δu=0.1 using the 5-axis machine (kinematic axis: X, Y, Z, A, and C)

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Figure 8

The machining simulation for parameter increment Δu=0.07

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Figure 9

The machining simulation for parameter increment Δu=0.05

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Figure 1

The relative position between the toroidal cutter and the design surface

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Figure 3

Different locations of the toroidal cutter in adjacent passes for the zig-zag form

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Figure 4

The algorithm for calculating the minimum distance between the circular curve K of tool and the design surface S

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Figure 5

The test surface

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Figure 6

The local magnified error curve for the tool position (u=v=0.5)

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