Abstract:The efficiency of multi-axis NC machining of sculptured surface parts is significant because the equipment is very expensive and typically highly utilized, requiring capital expenditures proportional to machining time per part. The paper describes a general approach for calculation of the productivity of multi-axis NC machining of sculptured part surfaces.Equations are derived to estimate the productivity of rough and finish machining and to calculate maximum feed rates. A new type of function (called the function of conformity of a sculptured surface to be machined and machining surface of the tool) are introduced as geometric analogs of productivity of part surface machining. This function considerably simplifies the analytical description of the geometric and kinematic aspects of the process of multi-axis machining and allows calculation of optimal parameters for the machining process. INTRODUCTIONThe efficiency of machining of surfaces is a critical factor in many manufacturing processes. Most efficient machining means the cheapest machining of the parts with the required dimensions, tolerances and quality in the shortest time (Amirouche, 1993; Bollinger, et aI., 1988;Chen, Y.D., et al., 1993; Gregory and Ozsoy, 1987; Radzevitch, 1991;.The efficiency of NC machining of sculptured part surfaces on multi-axis machine tools is an important cost component of many manufacturing processes. There are numerous approaches to evaluate machining efficiency. The most general criterion is the expense of machining parts of a specified quality. An economic approach to multi-axis NC machining of sculptured part surfaces has been developed (Ludema, et al., 1987). This provides a good criterion applicable for any type of machining and yields quite accurate results, but it is quite complex, and its analytical description is bulky, so it is not widely applied. There is another criterion for machining efficiency -the machining time per part. This criterion has a simple analytical description, but its application is restricted to comparison of the efficiency of machining of the same, or at least similar, part surfaces.There are many ways to evaluate and increase the efficiency of multi-axis NC machining of sculptured part surfaces. Optimal rough machining of sculptured parts on a CNC milling machine was studied by (Dong and Vickers, 1993), using a least machining time approach. The method considerably improved productivity and reduced production costs. Research on the kinematics of three-and five-axis CNC machining Yang, 1991 and1992) has improved the efficiency of machining operations. Other investigations shared similar goals
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