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Research Papers

Iso-Planar Feed Vector-Fields-Based Streamline Tool Path Generation for Five-Axis Compound Surface Machining With Torus-End Cutters

[+] Author and Article Information
Shuoxue Sun

School of Mechanical Engineering,
Dalian University of Technology,
Dalian 116024, China
e-mail: shuoxue_sun@163.com

Yuwen Sun

School of Mechanical Engineering,
Dalian University of Technology,
Dalian 116024, China
e-mail: xiands@dlut.edu.cn

Jinting Xu

School of Automotive Engineering,
Dalian University of Technology,
Dalian 116024, China
e-mail: xujt@dlut.edu.cn

Yuan-Shin Lee

Department of Industrial and
Systems Engineering,
North Carolina State University,
Raleigh, NC 27695
e-mail: yslee@ncsu.edu

1Corresponding author.

Manuscript received September 8, 2017; final manuscript received March 9, 2018; published online May 14, 2018. Editor: Y. Lawrence Yao.

J. Manuf. Sci. Eng 140(7), 071013 (May 14, 2018) (11 pages) Paper No: MANU-17-1560; doi: 10.1115/1.4039653 History: Received September 08, 2017; Revised March 09, 2018

This paper presents a new vector-field-based streamline smoothing method in the parametric space and a tool orientation optimization technique for five-axis machining of complex compound surfaces with torus-end cutters. Iso-planar tool path is widely used in the machining of various types of surfaces, especially for the compound surface with multiple patches, but the operations of intersecting the compound surface with a series of planes have depended considerably on the complicated optimization methods. Instead of intersecting the surface directly with planes, a novel and effective tool path smoothing method is presented, based on the iso-planar feed vector fields, for five-axis milling of a compound surface with torus-end cutters. The iso-planar feed vector field in the parametric domain is first constructed in the form of stream function that is used to generate the candidate streamlines for tool path generation. Then, a G1 blending algorithm is proposed to blend the vector fields within the adjacent parametric domains to ensure smooth transition of cross-border streamlines. Based on the smoothened streamlines in the parametric domains, pathlines along with their correspondent side sizes are selected as desirable tool paths. Concerning a high performance machining, detailed computational techniques to determine the tool axis orientation are also presented to ensure, at each cutter contact (CC) point, the torus-end cutter touches the part surface closely without gouging. Both the computational results and machined examples are demonstrated for verification and validation of the proposed methods.

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Figures

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Fig. 1

The iso-planar feed directions of the part surface and their associated parameter directions

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Fig. 2

Adjacent vector fields blending: (a) the original vector fields with G0-continuity streamlines at the shared boundary and (b) the blended vector fields with G1-continuity streamlines at the shared boundary

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Fig. 3

Geometric transformation of the cutter and part surface

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Fig. 4

Normal curvature in an arbitrary direction

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Fig. 5

Gouge checking between the cutter and the part surface

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Fig. 6

The calculated PEs on each side of the CC point

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Fig. 7

Comparison of tool PE before and after optimizing the tilt angle

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Fig. 8

Tool path arrangement in the parametric domain

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Fig. 9

Two compound surfaces: (a) the two-patch compound surface and (b) the four-patch compound surface

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Fig. 10

Tool path scheduling for the two-patch compound surface: (a) vector-field-based tool paths and (b) iso-planar tool paths

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Fig. 11

Machining simulation of the two-patch compound surface: (a) machined surface by the vector-field-based tool paths and (b) machined surface by the iso-planar tool paths

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Fig. 12

Tool path scheduling for the four-patch compound surface: (a) the vector-field-based tool paths; (b) the iso-planar tool paths generated with the patch-by-patch strategy; and (c) the magnified views of the interface of two patches

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Fig. 13

Surface machined by the proposed tool paths: (a) machining experiment of vector-field-based tool paths; (b) machining experiment of the iso-planar tool paths; and (c) the magnified views of the interface of two patches

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Fig. 14

Comparison of model surface profiles and CMM scans

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