Numeric implementation of drop and tilt method of 5-axis tool positioning for machining of triangulated surfaces

Abstract

In this paper, we present an algorithm to find a gouge-free, multipoint of contact tool path for machining a triangulated surface. The algorithm is based on a proven 3-axis method of dropping a generalized radiused end mill on to a triangulated surface to find a gouge-free tool position. This algorithm is wrapped within the bisection algorithm to find a gouge-free 5-axis tool position that touches the triangulated part at two or more points. Our algorithm does not require solving systems of nonlinear equations and has been tested on several parts.

A new approach to find gouge free tool positions for a toroidal cutter for Bézier surfaces in five-axis machining

“…As mentioned by Duvedi et al [6,15,17] a rotation about the axis of this pseudo-insert maintains the contact between tool and surface at P . The earlier works [6,15] tilted the tool about this axis thereby complicating the resulting drop equations and ray firing equations as transcendental terms due to rotation come into play. In this paper, we use the approach of [17], where the surface is rotated rather than the tool to find the second point of contact and the tool orientation.…”

“…The method used in this paper is to position the tool in close proximity to the surface is to inclined the tool to make contact at least at two different points on the surface at the same time. A tool positioning method based on this attribute is known as a Multipoint Method (MPM) [5][6][7][8][9][10].…”

“…The MPM method has evolved to the Drop and Tilt method of Duvedi et al for both triangulated surfaces [5,6] and for tensor product Bézier surfaces [14][15][16][17]. The implementation of Duvedi et al [17] involves dropping the toroidal tool onto the surface using Newton's method to find a point of tangency between the tool and the surface.…”

Enhanced Dual Contouring for Continuous Surface Reconstruction: A Novel Method in Real-Time Geometric Visualization for CNC Machining Simulation

“…Geometric simulation primarily focuses on the movement and geometrical shapes of the tool and workpiece without considering cutting parameters, cutting forces, or other physical parameters. Its purpose is to verify the correctness of NC programs, reduce production costs, and shorten the design and manufacturing cycles of workpieces [4] [5][6] [7] [8]. In contrast, physical simulation predicts tool wear and vibration by simulating physical quantities in the actual cutting process to optimize cutting techniques [9], thereby increasing the production success rate of the workpieces.…”