A fuzzy basis material removal optimization strategy for sculptured surface machining using ball-nosed cutters W. L. R. IP²Optimizing the e ciency in cutting a sculptured surface using numerically controlled machining techniques needs to carefully consider the relationship between cutting edges and surface geometry. The actual cutting speed at the cutting edges of a ball-nosed cutter is a dependent parameter to the surface gradient of the machined surface. A fuzzy basis material removal optimization approach was suggested to compensate the variation of cutting speed due to the change of gradient on the sculptured surface in machining process. In this approach, a constant cutting force is maintained by adjusting the cutting feedrate for each cutting point in considering other machining parameters, such as tool life and surface gradient. The results from a machining trial indicated that the total amount of removed material collected at a ® xed time interval with feedrate adjustment from the machined surface was about 41% more than the surface machined at a constant feedrate. In considering computational time, using the fuzzy approach can also be a faster way than employing heuristic methods. In addition, using the fuzzy approach is simple due to its computational complexityindependent properties in operating a fuzzy inference system.
The assessment of manufactured surfaces by coordinate metrology techniques has changed in recent years. Speed, accuracy and flexibility have all improved with the introduction of coordinate measuring machines (CMM). However, some technical problems have yet to be solved, in particular those pertaining to free-form surfaces. This paper considers the influence of surface features and probe tip geometry on the assessment of free-form surfaces. Inaccurate measurements due to the problems of probe tip diameter and undulating surface curvature have been investigated, and a simple mathematical compensation technique for different probe diameters and an adaptive measuring point planning strategy have been developed. Experimental data confirm that the measuring errors are significantly reduced when the probe tip diameter compensation approach is used. The problems of machined surface measurement have also been considered and a method, namely least-squares data fitting, is proposed to give a better qualifying technique for the cusped surfaces. This new technique has been implemented and the results from the case study indicate that the least-squares method can give a more precise representation of the quality of a machined surface than standard statistical measurement systems. Experimentation also indicates that the results of the least-squares data fitting method are consistent with the CMM computed values, which verifies the reliability of the method.
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