Abstract
Tool path generation is one of the key challenges in multi-axis sculptured surface machining. Besides geometry accuracy, machining processes have been considered in tool path generation in order to improve machining quality and efficiency as far as possible. However, so far, the machine tool accuracies have not been yet fully taken into account during tool path generation. Contour accuracy is one of the most important precision indexes to guarantee the machining quality of sculptured surfaces. One of the major reasons causing contour error is the dynamic mismatch between feed axes of machine tools. In this study, the mathematic relationship between the cutting direction, dynamic mismatch of feed axes and contour error is theoretically established. The mathematic relationship can be used to calculate the optimal cutting directions which minimize the contour error caused by dynamic mismatch between feed axes during machining a sculptured surface by a three-axis machine tool. A machining experiment is carried out to verify the mathematic relationship. In the experiment, the tool paths are generated along the optimal cutting direction and other cutting directions for comparison. The results show that the contour error under the case of the optimal cutting direction is much smaller than that under the other cases.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Loney GC, Ozsoy TM (1987) NC machining of free form surfaces. Comput Aided Des 19(2):85–90
Bobrow James E (1985) NC machine tool path generation from CSG part representations. Comput Aided Des 17(2):69–75
Elber G, Cohen E (1994) Toolpath generation for freeform surface models. Comput Aided Des 26(6):490–496
Lo CC (2000) CNC machine tools surface interpolator for ball-end milling of free-form surfaces. Int J Mach Tool Manu 40(3):307–326
Huang Y, Oliver JH (1994) Non-constant parameter NC tool path generation on sculptured surfaces. Int J Adv Manuf Technol 9(5):281–290
Park SC, Choi BK (2000) Tool-path planning for direction-parallel area milling. Comput Aided Des 32(1):17–25
Sarma SE (2000) The crossing function and its application to zig-zag tool paths. Comput Aided Des 31(4):881–890
Lartigue C, Thiebaut F, Maekawa T (2001) CNC tool path in terms of B-spline curves. Comput Aided Des 33(4):307–309
Suresh K, Yang DCH (1994) Constant scallop-height machining of free-form surfaces. Journal of Engineering for Industry 116:253–259
Lo CC (1999) Efficient cutter-path planning for five-axis surface machining with a flat-end cutter. Comput Aided Des 31:557–566
Lee YS (1998) Non-isoparametric tool path planning by machining strip evaluation for 5-axis sculptured surface machining. Comput Aided Des 30(7):559–570
Harik RF, Gong H, Bernard A (2013) 5-axis flank milling: a state-of-the-art review. Comput Aided Des 45:796–808
Marciniak K (1987) Influence of surface shape on admissible tool positions in 5-axis face milling. Comput Aided Des 19(5):233–236
Kruth JP, Klewais P (1994) Optimization and dynamic adaptation of the cutter inclination during five-axis milling of sculptured surfaces. CRIP Annals-Manufacturing Technology 43(1):443–448
Chiou CJ, Lee YS (2002) A machining potential field approach to tool path generation for multi-axis sculptured surface machining. Comput Aided Des 34(5):357–371
Kim T, Sarma SE (2002) Tool path generation along directions of maximum kinematic performance; a first cut at machine-optimal paths. Comput Aided Des 34(6):453–468
Giri V, Bezbaruah D, Bubna P, Choudhury AR (2005) Selection of master cutter paths in sculptured surface machining by employing curvature principle. Int J Mach Tool Manu 45(10):1202–1209
Lim EM, Menq CH (1997) Integrated planning for precision machining of complex surfaces. Part 1: cutting-path and feedrate optimization. Int J Mach Tool Manu 37(1):61–75
Erkorkmaz K, Altintas Y (2001) High speed CNC system degisn. Part 1: jerk limited trajectory generation and quintic spline interpolation. Int J Mach Tool Manu 41:1323–1345
Held M, Spielberger C (2009) A smooth spiral tool path for high speed machining of 2D pockets. Comput Aided Des 41:539–550
Li LL, Zhang YF, Li HY, Geng L (2011) Generating tool-path with smooth posture change for five-axis sculptured surface machining based on cutter’s accessibility map. Int J Adv Manuf Technol 53:699–709
Zheng G, Bi QZ, Zhu LM (2012) Smooth tool path generation for five-axis flank milling using multi-objective programming. Proc Inst Mech Eng B J Eng Manuf 226:247–254
Yuen A, Zhang K, Altintas Y (2013) Smooth trajectory generation for five-axis machine tools. Int J Mach Tools Manuf 71:11–19
Ernesto CA, Farouki RT (2010) Solution of inverse dynamics problems for contour error minimization in CNC machines. Int J Adv Manuf Technol 49(5-8):589–604
Rahaman M, Seethaler R, Yellowley I (2015) A new approach to contour error control in high speed machining. Int J Mach Tools Manuf 88:42–50
Kim Y-J, Elber G, Bartoň M, Pottmann H (2015) Precise gouging-free tool orientations for 5-axis CNC machining. Comput Aided Des 58:220–229
Bo PB, Bartoň M, Plakhotnik D, Pottmann H (2016) Towards efficient 5-axis flank CNC machining of free-form surfaces via fitting envelopes of surfaces of revolution. Comput Aided Des 79:1–11
Li BT, Hong J, Liu ZF (2014) Stiffness design of machine tool structures by a biologically inspired topology optimization method. Int J Mach Tools Manuf 84(2):33–44
Gao XM, Li BT, Hong J, Guo JK (2016) Stiffness modeling of machine tools based on machining space analysis. Int J Adv Manuf Technol 86(5–8):2093–2106
Altintas Y, Verl A, Brecher C, Uriarte L, Pritschow G (2011) Machine tool feed drives. CIRP Annals-Manufacturing Technology 60:779–796
Huo F, Poo AN (2013) Precision contouring control of machine tools. International Journal of Advance Manufacture Technology 64:319–333
Poo AN, Bollinger JG, Younkin GW (1972) Dynamic errors in type 1 contouring systems. IEEE Transaction on Industry Applications IA-8(4):477–484
Xi XC, Poo AN, Hong GS (2009) Improving contouring accuracy by tuning gains for a bi-axial CNC machine. Int J Mach Tool Manu 49:395–460
Yeh SS, Hsu PL (2004) Perfectly matched feedback control and its integrated design for multi-axis motion system. Journal of Dynamic System Measure and Control 126(3):547–557
Lei WT, Paung IM, CC Y (2009) Total ballbar dynamic tests for five axis CNC machine tools. Int J Mach Tool Manu 49:488–499
Lin MT, SK W (2013) Modeling and analysis of servo dynamics errors on measuring paths of five axis machine tools. Int J Mach Tool Manu 66:1–14
Jiang Z, Ding JX, Song ZY (2016) Modeling and simulation of surface morphology abnormality of S test piece machined by five axis CNC machine tool. International Journal of Advance Manufacture and Technology 85:2745–2759
Sencer B, Altintas Y, Croft E (2008) Feed optimization for five-axis CNC machine tools with drive constraints. Int J Mach Tool Manu 48:733–745
Jin YA, He Y, JZ F (2013) A look-ahead and adaptive speed control algorithm for parametric interpolation. International Journal of Advanced Manufacture Technology 69:2613–2620
Funding
This work is financially supported by the project of the National Natural Science Funds of China (Grant No. 51775421), the Major Project of High-end CNC Machine Tool and Basic Manufacturing Equipment of China (Grant No. 2015ZX04001002), and the Project funded by China Postdoctoral Science Foundation (Grant No. 2015M570824).
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Lu, D., Liu, S., Li, X. et al. Optimal cutting directions by considering the dynamic mismatch between feed axes of machine tools. Int J Adv Manuf Technol 95, 1607–1615 (2018). https://doi.org/10.1007/s00170-017-1243-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-017-1243-8