Machinability Analysis for 3-Axis Flat End Milling

[+] Author and Article Information
Ye Li

Department of Industrial and Manufacturing Systems Engineering, Iowa State University, Ames, IA 50011yeli@iastate.edu

Matthew C. Frank

Department of Industrial and Manufacturing Systems Engineering, Iowa State University, Ames, IA 50011

J. Manuf. Sci. Eng 128(2), 454-464 (Aug 08, 2005) (11 pages) doi:10.1115/1.2137748 History: Received October 13, 2004; Revised August 08, 2005

This paper presents a method for geometric machinability analysis. The implementation of the strategy determines the machinability of a part being processed using a plurality of 3-axis machining operations about a single axis of rotation for setup orientations. Slice file geometry from a stereolithography model is used to map machinable ranges to each of the line segments comprising the polygonal chains of each slice. The slices are taken orthogonal to the axis of rotation, hence, both two- and three-dimensional (2D and 3D) machinability analysis is calculated for perpendicular and oblique tool orientations, respectively. This machinability approach expands upon earlier work on 2D visibility analysis for the rapid manufacturing and prototyping of components using CNC machining.

Copyright © 2006 by American Society of Mechanical Engineers
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Figure 1

Accessibility based on light ray and a sized tool

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Figure 2

Setup for rapid machining

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Figure 3

Process steps for rapid machining

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Figure 4

Illustration of machinability for perpendicular case

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Figure 5

Illustration of maximum tool space under oblique cutting

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Figure 6

Variation of effective obstacles

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Figure 7

Variation of machinable range due to the existance of an obstacle segment

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Figure 8

Geometric Transformation

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Figure 9

An obstacle polygon in y-z plane

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Figure 10

An obstacle polygon in D-T plane

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Figure 11

Machinability graph

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Figure 12

Machinability of a half cylinder extrusion pocket

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Figure 13

2D views of machinable profiles

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Figure 14

Screen shot of example part virtually machined in MasterCAM

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Figure 15

Machining result of a “jack” model

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Figure 16

Machined “jack” surface in MasterCAM

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Figure 17

Identification of nonmachinable regions for “jack”



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