A New Approach to Planning Plungers Paths for Efficient 2½-Axis Computer Numerically Controlled Plunge Milling of Complex Pockets With Islands

Abstract

Plunge milling is an effective roughing operation, especially in pockets roughing, because it can efficiently remove a large amount of stock material without high manufac turing costs. However, plunge milling o f complex pockets with islands, whose boundaries could be designed with free-form curves, is quite challenging for multiple plungers have to be used including small plungers to cut necks between islands and their plungers paths are expected to have fewer times of plunging and shorter travel to achieve efficient machining. Unfortunately, little research on this topic was carried out in the past, and the challenge has not been addressed yet. In this research, a new approach is proposed to generate plunger paths for efficient plunge milling of the complex pockets. Its main features include (1) packing plunger circles at a minimum number of locations inside the pocket for fewer times of plunging, (2) placing plunger circles to cover the areas enclosed by the afore-packed circles to clear out the interior pocket material, and (3) planning the shortest paths to connect plunger locations for less traveling time. The advantages of this new approach over the overlapped circles filling (OCfill) and the Catia methods are dem onstrated with two examples, and it can be directly used for pocket plunge milling in industry.

Efficient plunge milling cutter and process for two-dimensional cavity

“…This strategy can better take into account machining e ciency and cutter life. Chen [27] et al proposed a process strategy using multiple speci cations of plunge milling cutters for complex cavities with islands, and established a calculation method of cutter location points. The above process researches of plunge milling mainly include material residue, cutter path, cutter axis vector and machining parameters, etc.…”

A modeling and prediction method for plunge cutting force considering the small displacement of cutting layer

“…Wakaoka et al 1 studied the geometrical angle of the plunge cutting tool and the influence of the plunge cutting process on the perpendicularity of the high-precision vertical plane. Chen and Abdelkhalek 2 established a new approach to generate the shortest paths for pocket plunge milling. Witty et al 3 investigated the performance and stability of plunge milling; the meshing state of the tool analyzed according to micro-geometry of the tool and the milling process parameters.…”