Efficient Toolpath Generation Method for High-Quality and High-Accuracy Machining of Curved Surfaces

Abstract

Currently, there is no function in commercial CAM systems to generate optimal quality machining for curved surfaces. In computer-aided manufacturing (CAM) systems, the toolpath (cutter location data) is derived as an approximately straight-line segment based on a plane approximation surface instead of a free-form surface from the designed shape. Due to this approximation, machining accuracy and quality are decreased, especially in the region with characteristic lines like in an outer automobile covering part. This paper presents an algorithm procedure for toolpath generation to process complex parts with characteristic curves with high-quality and high-accuracy machining by dividing the surface into different regions, the region where machining accuracy is not required as a plane approximation surface and the remaining region where accuracy is required as free-form surfaces. The proposed method was confirmed by machining experiments that actual machining realized high machining quality and accuracy compared to the conventional CAM system.

Prediction of Actual Toolpath and Enhancement of the Toolpath Accuracy Based on Identification of Feedrate Change Characteristics of Machine Tool

“…Curved surfaces are frequently employed to represent models in various industries such as automotive manufacturing, aerospace, and mold production. With the growing demands within the manufacturing sector, there is a pressing need to enhance the precision of numerical control (NC) machining to meet these requirements (Chen et al, 2023;Dat, Phong, and Phuc, 2022;Tunc et al, 2019;Yan et al, 2015;Lazoglu, Manav, and Murtezaoglu, 2009;Wang, Yu, and Liao, 2006). Machining errors due to tool deflection are an essential issue in the machining process (Changqing et al, 2020;Ghorbani and Movahhedy, 2019;Ma et al, 2018;Budak et al, 2004).…”

“…In addition to that, the correction of complex shapes and Acc/Dec adjustment in the machine tool for high speed and precision are also performed by these functions. On the other hand, almost all current generations of CNC machines use conventional control functions; the prediction of speed change and actual toolpath without AI/GI function was presented (Dat and Aoyama, 2019). In our study, toolpath prediction, measurement, and evaluation of the proposed method are performed with the AI function enabled.…”