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Research Papers

Quantitative Comparison of Pocket Geometry and Pocket Decomposition to Obtain Improved Spiral Tool Path: A Novel Approach

[+] Author and Article Information
Divyangkumar D. Patel

Mechanical Engineering Department,
Sardar Vallabhbhai National Institute of Technology,
Surat, Gujarat 395007, India
e-mail: dd.divyang@gmail.com

Devdas I. Lalwani

Associate Professor
Mechanical Engineering Department,
Sardar Vallabhbhai National Institute of Technology,
Surat, Gujarat 395007, India
e-mail: dil@med.svnit.ac.in

1Corresponding author.

Manuscript received June 16, 2016; final manuscript received September 22, 2016; published online January 27, 2017. Assoc. Editor: Radu Pavel.

J. Manuf. Sci. Eng 139(3), 031020 (Jan 27, 2017) (10 pages) Paper No: MANU-16-1338; doi: 10.1115/1.4034896 History: Received June 16, 2016; Revised September 22, 2016

In the 2.5D pocket machining, the pocket geometry (shape of the pocket) significantly affects the efficiency of spiral tool path in terms of tool path length, cutting time, surface roughness, cutting forces, etc. Hence, the pocket geometry is an important factor that needs to be considered. However, quantitative methods to compare different pocket geometries are scarcely available. In this paper, we have introduced a novel approach for quantitative comparison of different pocket geometries using a dimensionless number, “DN.” The concept and formula of DN are developed, and DN is calculated for various pocket geometries. A concept of percentage utilization of tool (PUT) is also introduced and is considered as a measure and an indicator for a good tool path. The guidelines for comparing pocket geometries based on DN and PUT are reported. The results show that DN can be used to predict the quality of tool path prior to tool path generation. Further, an algorithm to decompose pocket geometry into subgeometries is developed that improves the efficiency of spiral tool path for bottleneck pockets (or multiple-connected pocket). This algorithm uses another dimensionless number “HARIN” (HARI is the acronym of “helps in appropriate rive-lines identification” and suffix “N” stands for number) to compare parent pocket geometry with subgeometries. The results indicate that decomposing pocket geometry with the new algorithm improves HARIN and removes the effect of bottlenecks. Furthermore, the algorithm for decomposition is extended for pockets that are bounded by free-form curves.

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Figures

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Fig. 2

Pocket geometries along with EAC, EPC, MEC, and LEC: (a) triangular shaped, (b) plus shaped, and ((c) and (d)) octagonal shaped with spike protruding outside and inside, respectively

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Fig. 3

((a)–(g)) Trend of D0, D1, D2, D3, D4, D5, and Ce along with PUT, respectively, for various pocket geometries

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Fig. 4

((a)–(e)) Spiral tool path, LEC, EAC, EPC, and MEC for different regular polygonal geometries and (f) plot showing comparison of DN, DNspiral, and PUT

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Fig. 5

((a)–(e)) Spiral tool path, LEC, EAC, EPC, and MEC for different plus-shaped geometries and (f) plot showing comparison of DN, DNspiral, and PUT

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Fig. 6

((a)–(e)) Spiral tool path, LEC, EAC, EPC, and MEC for different triangular-shaped geometries and (f) plot showing comparison of DN, DNspiral, and PUT

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Fig. 7

((a)–(e)) Spiral tool path, LEC, EAC, EPC, and MEC for different rectangular-shaped geometries and (f) plot showing comparison of DN, DNspiral, and PUT

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Fig. 8

((a)–(e)) Spiral tool path, LEC, EAC, EPC, and MEC for different irregular-shaped geometries and (f) plot showing comparison of DN, DNspiral, and PUT

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Fig. 9

((a)–(e)) Spiral tool path, LEC, EAC, EPC, and MEC for different elliptical-shaped geometries and (f) plot showing comparison of DN, DNspiral, and PUT

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Fig. 10

Plot of DN and PUT in decreasing order of DN

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Fig. 11

Polygon before decomposition with possible spit lines for typical bottleneck corner

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Fig. 12

Spiral tool path on decomposed polygon

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Fig. 13

Examples of pocket decomposition on H-, S-, and M-shaped pockets

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Fig. 14

Split line (rive line) determination using Pi and Pj  and spiral tool path for two different free-form pockets (i.e., (a) and (b)) after pocket decomposition

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Fig. 15

A pocket with an island

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