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research-article

Iso-planar Feed Vector Fields Based Streamline Tool Path Generation for 5-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
shuoxue_sun@163.com

Yuwen Sun

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

Jinting Xu

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

Yuan-Shin Lee

Department of Industrial and Systems Engineering, North Carolina State University, Raleigh, NC 27695, USA
yslee@ncsu.edu

1Corresponding author.

ASME doi:10.1115/1.4039653 History: Received September 08, 2017; Revised March 09, 2018

Abstract

This paper presents a new vector field based streamline smoothing method in the parametric space and a tool orientation optimization technique for 5-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 the planes, a novel and effective tool path smoothing method is presented, based on the iso-planar feed vector fields, for the 5-axis milling of a compound surface with torus-end cutters. The iso-planar feed vector field in the parametric domain is first constructed in 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 the cross-border streamlines. Based on the smoothened streamlines in the parametric domains, pathlines along with their correspondent side sizes are selected as the 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 laboratory machined examples are demonstrated for verification and validation of the proposed methods.

Copyright (c) 2018 by ASME
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