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Research Papers

Improved Rotary Contact Method for 5-Axis Sculptured Surfaces Machining

[+] Author and Article Information
Wengang Fan

e-mail: wgfan.alan@gmail.com

Peiqing Ye

e-mail: yepq@tsinghua.edu.cn

Chenxi Fang

e-mail: f050514108@126.com

Shaohua Shi

e-mail: ssh06@mails.tsinghua.edu.cn
The State Key Laboratory of Tribology,
Beijing Key Lab of Precision/Ultra-Precision
Manufacturing Equipments and Control,
Department of Mechanical Engineering,
Tsinghua University,
Beijing 100084, China

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received July 16, 2012; final manuscript received June 27, 2013; published online September 11, 2013. Assoc. Editor: Tony Schmitz.

J. Manuf. Sci. Eng 135(5), 051002 (Sep 11, 2013) (6 pages) Paper No: MANU-12-1212; doi: 10.1115/1.4025062 History: Received July 16, 2012; Revised June 27, 2013

The 5-axis tool positioning strategy named rotary contact method (RCM) for sculptured surfaces machining has been developed in our previous paper (Fan et al., 2012, “Rotary Contact Method for 5-Axis Tool Positioning,” Trans. ASME J. Manuf. Sci. Eng., 134(2), p. 021004). The RCM finds the optimal tool positions by rotating the tool backward based on the offset surface, and can generate big machined strip width. However, the RCM can only guarantee a contact point because of the design surface's geometric asymmetry in most cases, which leads to the poor surface quality. To resolve this problem, the improved rotary contact method (IRCM) is developed in this paper. The parametric equation of the circular curve of the toroidal cutter defined by the backward and the sideward tilt angle of the tool is strictly deduced. According to the nested optimization of the two tool's angles, there are two contact points found between the tool's cutting surface and the design surface around the feed direction without gouging. Tool positions investigation, machining simulation and cutting experiment are all performed based on a test surface. The results verify the correctness and effectiveness of the IRCM and show that the IRCM can apparently improve the surface quality compared to the RCM.

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References

Figures

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Fig. 1

Schematic diagram of the IRCM

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Fig. 2

Tool positioning situation for adjacent tool paths

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Fig. 5

Two local machining error curves generated by the IRCM and the RCM

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Fig. 7

Simulation result in the VERICUT software

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Fig. 8

Machined test surface

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Fig. 9

CMM scans and model surface cross-sections for the IRCM

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Fig. 3

Flowchart for optimizing the backward and sideward tilt angle of the tool

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Fig. 6

Tool paths generated by the IRCM and the nonisoparametric curve method

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