Constant Engagement Tool Path Generation to Enhance Machining Accuracy in End Milling

Uddin, Md. Sharif; Ibaraki, Soichi; Matsubara, Atsushi; Nishida, Satoru; Kakino, Yoshiaki

doi:10.1299/jsmec.49.43

Cited by 20 publications

(12 citation statements)

References 6 publications

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“…Through experiments, Uddin et al proved that this strategy ensures more appropriate dimensionally accurate machining as compared to tool paths generated through conventional uniform offsets. This finding supports the notion that, due to constant engagement, cutting force variation will decrease, and so will the impact of flexible shape change [49]. All the above-mentioned solutions construct the tool path in small sections, analyse the relations and construct the tool and workpiece engagement from point to point.…”

Section: Introductionsupporting

confidence: 75%

The fast constant engagement offsetting method for generating milling tool paths

Jacsó

Mátyási

Szalay

2019

Int J Adv Manuf Technol

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It is a well-established fact that when equidistant tool paths are used for 2.5D milling operations tool load varies based on the functions of path curvature. This phenomenon makes the optimal selection of cutting parameters more difficult, and the local load peaks are also detrimental to machining stability and tool life. Numerous publications address possible solutions to eliminate the problems caused by varied cutting parameters. The best solution for this is to keep the cutter engagement at a constant value. Nowadays, several methods are available to generate tool paths which are able to maintain constant cutter engagement, but the widespread use of such solutions is significantly hindered, because in this scenario complex calculations are required. This article offers a solution to this problem by presenting a new non-equidistant offsetting method for ensuring a constant cutter engagement angle. The algorithm developed for this purpose is based on simple geometrical equations and allows for its widespread use just like pixel-based methods. Concerning this new solution, computation needs and uniform tool load are verified by simulation and through experiments. The experiments have shown favourable results. Keywords Tool path generation. Cutter engagement. High-speed milling. Cutting force. Non-equidistant offsetting Nomenclature a e Effective radial immersion [mm] a p Axial depth of cut [mm] c(t) Parametric representation of workpiece contour [{mm, mm}] f z Feed per tooth [mm] h ex Maximum chip thickness [mm] i, j Step index [−] n Spindle speed [1/min] p(t) Parametric representation of tool path [{mm, mm}] r tool Tool radius [mm] s Stepover [mm] t Free parameter of curve equations [−] v Feed vector [{mm, mm}] v c Cutting speed [m/min] v f Feed rate [mm/min] w Trochoidal step [mm] z Number of teeth [−] C Entry point of the cutting edge [{mm, mm}] D tool Tool diameter [mm] MRR Material removal rate [mm 3 /min] P Tool path point [{mm, mm}] Q Exit point of cutting edge [{mm, mm}] V(x, y) Vector field [{mm, mm}, {mm, mm}] a, β Angle parameters [ ∘ ] Δs Stepsize[−] θ Cutter engagement angle [ ∘ ]

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Section: Introductionsupporting

confidence: 75%

The fast constant engagement offsetting method for generating milling tool paths

Jacsó

Mátyási

Szalay

2019

Int J Adv Manuf Technol

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“…Best results are obtained in conjunction with the approach described by (Uddin et al, 2006), which also ensures constant tool engagement at the finishing stage. More precisely, the proposed roughing algorithm should be applied on the precut semifinishing surface obtained with the backward algorithm for the finishing tool.…”

Section: Resultsmentioning

confidence: 99%

“…For large tool diameters, relative to the part curvature, the precut surface obtained may require a much smaller tool at the previous step, which limit the usefulness of the strategy in roughing operations. Uddin et al (2006) applied the backward generation approach for correcting the semi-finishing paths in order to obtain tighter tolerance on the finished part.…”

Section: Related Workmentioning

confidence: 99%

Automatic Generation of Milling Toolpaths with Tool Engagement Control for Complex Part Geometry

Dumiţrache

Borangiu

Dogar

2010

IFAC Proceedings Volumes

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“…17 Values of engagement angle for machining linear, concave and convex surfaces with same radial depth of cut (Table 1) are not the same. 19 There is an analytical relation between radial depth of cut and engagement angle including influence of machining surface radius, tool radius and radial depth of cut.…”

Section: Tool Path Influence On Cutting Parametersmentioning

confidence: 99%

“…Cutting load regulation based on feed rate pre-scheduling was widely studied. 20 The approaches to adapt or modify the tool path for achieving a constant load were much less studied, 19,[21][22][23] although they are independent from the cutting tool diameter, length, number of flutes and work piece material. High-quality tool materials for wood machining enables high cutting speeds and feed rates, with relatively low cutting forces, and therefore researches of tool path influence on machining time, tool wear and dynamic stability are neglected.…”

Section: Tool Path Influence On Cutting Parametersmentioning

confidence: 99%

Optimisation of tool path for wood machining on CNC machines

Petrović

Lukic

Ivanović

et al. 2016

Proceedings of the Institution of Mechanical Engineers, Part C:

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Peripheral pocket or contour milling in wood machining, using flat end milling tool, can be performed with different tool paths. Technology designers of multi axis CNC wood machining use their experience and intuition to choose some of the options offered by CAM systems that determine the final shape of tool path, thus the generated tool path largely depend on individual judgment. Minimum cutting force, maximum dynamic stability of the process and minimum tool wear are achieved, or some other technological requirements are met, by using optimal tool path. Tool path optimisation is based on analysis of possible tool paths and determination of cutting parameters which are dependable of chosen tool path and are affecting the main wood processing factors. Axial and radial depth of cut, engagement angle, feed and feed rate profile are identified as key parameters dependable of tool path, and their values and variations along the tool path influence the cutting speed, tool wear and cutting force. Knowledge of values and changes of those key machining parameters along the tool path is necessary for simulation and monitoring of the main cutting factors during the wood machining process. NC code transformation methodology and generation of tool path parameters necessary for calculating all elements needed for tool movement simulation from given NC programs are shown. Blank and tool mathematical description are used with tool movement information for simulation of wood machining process. Simulation of cutting parameters and their variation along the tool path, presented in this paper, can be used as bases for development of methodology for choosing the most adequate tool path for wood machining of given contour considering minimum cutting force and cutting force variation, minimum tool wear, maximum productivity or some other criteria.

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Constant Engagement Tool Path Generation to Enhance Machining Accuracy in End Milling

Cited by 20 publications

References 6 publications

The fast constant engagement offsetting method for generating milling tool paths

The fast constant engagement offsetting method for generating milling tool paths

Automatic Generation of Milling Toolpaths with Tool Engagement Control for Complex Part Geometry

Optimisation of tool path for wood machining on CNC machines

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