Methods for detecting errors in numerically controlled machining of sculptured surfaces

Jerard, Robert B.; Drysdale, Robert L. Scot; Hauck, Kenneth E.; Schaudt, Barry; Magewick, John

doi:10.1109/38.20331

Cited by 104 publications

(29 citation statements)

References 15 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…Solid modeling would seem to be ideal for NC simulation and verification; an exact representation of remaining material could be constructed. However, constructive solid geometry (CSG) application becomes O(n 4 ) and therefore unacceptable for any simulation of practical scale [12]. There does not appear to be extensive recent research in this area; most efforts have been focused on parametric boundary representation (Brep) methods (effectively a transition from solid to surface modeling).…”

Section: Related Workmentioning

confidence: 99%

“…After populating component surfaces with normal vectors (the density determined relative accuracy and computation time, though in O(n)), the vectors are trimmed as appropriate for each tool instance. Jerard [12] extended this simulation technique to verification and cutter location (CL) data correction. The most popular spatial discretization methodthe Z-buffer -was originally proposed by Van Hook [19].…”

Section: Related Workmentioning

confidence: 99%

See 1 more Smart Citation

Advanced process planning for subtractive rapid prototyping

Petrzelka

Frank

2010

Rapid Prototyping Journal

View full text Add to dashboard Cite

This paper presents process planning methods for Subtractive Rapid Prototyping, which deals with multiple setup operations and the related issues of stock material management. Subtractive Rapid Prototyping (SRP) borrows from additive rapid prototyping technologies by using 2½D layer based toolpath processing; however, it is limited by tool accessibility. To counter the accessibility problem, SRP systems (such as desktop milling machines) employ a rotary fourth axis to provide more complete surface coverage. However, layer-based removal processing from different rotary positions can be inefficient due to double-coverage of certain volumes. This paper presents a method that employs STL models of the in-process stock material generated from slices of the part along the rotation axis. The developed algorithms intend to improve the efficiency and reliability of these multiple layer-based removal steps for rapid manufacturing. IntroductionSubtractive Rapid Prototyping (SRP) is a considerably lesser known and utilized form of rapid prototyping technology, mainly due to continued challenges in the pre-process engineering and setup planning required. Subtractive operations in general afford excellent accuracy and repeatability, which is why it is more often utilized as an additional function of a hybrid-type rapid prototyping system that includes both additive and subtractive operations. Since the early days of RP technology, with systems such as Laminated Object Manufacturing (LOM), subtractive means have been employed as part of a solution alongside the conventional additive layer-based approaches. Although perhaps not purely subtractive, in LOM, a laser was used to cut the profile and surrounding support structures of each layer, after the layer of paper is added. In this manner, the additive approach enabled improved geometric capability while the laser cutting offered reasonable shaping accuracy. Later, the Sanders Modelmaker system, now used heavily in jewelry and dental manufacturing, utilized a machining process to accurately mill each deposited layer to a precise thickness. In a research project, Shape Deposition Manufacturing (SDM) used 5-axis machining in conjunction with a variety of deposition approaches to create both parts and molds. More recently, systems such as LAMP and Ultrasonic Consolidation (UC) continue to use subtractive means in an iterative manner to improve accuracy and surface finish. Desktop milling machines suitable for rapid prototyping have been marketed for lower-end materials in single or multisided machining operations, while lower-end, but more user-friendly SRP software systems such as Millit and Deskproto have attempted to facilitate the NC programming for these applications. To date, subtractive processes continue to be utilized in a few RP systems, while SRP-only systems have had limited success. The overwhelming success of RP technologies to date can be attributed almost solely to the additive-only machines; however, there are niche applications where an SRP system would b...

show abstract

Section: Related Workmentioning

confidence: 99%

Section: Related Workmentioning

confidence: 99%

Advanced process planning for subtractive rapid prototyping

Petrzelka

Frank

2010

Rapid Prototyping Journal

View full text Add to dashboard Cite

show abstract

“…It has been reported in the literature that the cost of simulation (i.e. the time) using constructive solid geometry (CSG) is proportional to the fourth power of the number of tool positions, Oðm 4 Þ [9]. It is certainly not unusual for a tool path to consist of thousands of tool positions, making solid modelling methods prohibitively expensive.…”

Section: Introductionmentioning

confidence: 99%

Mechanistic modelling of the milling process using an adaptive depth buffer

Roth

Ismail

Bedi

2003

Computer-Aided Design

View full text Add to dashboard Cite

“…1, an evaluation of the kinematical constraints is first performed, and then a local geometrical smoothing is carried out on the selected axis. If needed, a N-buffer technique [21] is used to control the geometrical deviation on the part. So a compromise has to be made between the smoothness and the geometrical tolerance.…”

Section: Introductionmentioning

confidence: 99%

5-Axis Flank Milling Tool Path Smoothing Based on Kinematical Behaviour Analysis

Beudaert

Pechard

Tournier

2011

AMR

View full text Add to dashboard Cite

Abstract. In the context of 5-axis flank milling, the machining of non-developable ruled surfaces may lead to complex tool paths to minimize undercut and overcut. The curvature characteristics of these tool paths generate slowdowns affecting the machining time and the quality of the machined surface. The tool path has to be as smooth as possible while respecting the maximum allowed tolerance. In this paper, an iterative approach is proposed to smooth an initial tool path. An indicator of the maximum feedrate is computed using the kinematical constraints of the considered machine tool, especially the maximum velocity, acceleration and jerk. Then, joint coordinates of the tool path are locally smoothed in order to raise the effective feedrate in the area of interest. Machining simulation based on a N-buffer algorithm is used to control undercut and overcut. This method has been tested in flank milling of an impeller and can be applied in 3 to 5-axis machining.

show abstract

Methods for detecting errors in numerically controlled machining of sculptured surfaces

Cited by 104 publications

References 15 publications

Advanced process planning for subtractive rapid prototyping

Advanced process planning for subtractive rapid prototyping

Mechanistic modelling of the milling process using an adaptive depth buffer

5-Axis Flank Milling Tool Path Smoothing Based on Kinematical Behaviour Analysis

Contact Info

Product

Resources

About