A three-dimensional configuration-space method for 5-axis tessellated surface machining
- 23 June 2008
- journal article
- research article
- Published by Informa UK Limited in International Journal of Computer Integrated Manufacturing
- Vol. 21 (5), 550-568
- https://doi.org/10.1080/09511920701263313
Abstract
This paper presents a three-dimensional configuration-space (3D C-space) machining method for 5-axis finish machining of tessellated surfaces. To maximize the step-over distance, the curvature matched method (CM2) is used to approximate the cusp height and the step-over distance. A 3D C-space is then built for each cutter contact point (CC point). Every configuration set in this 3D C-space guarantees that the cutter is gouge-free and that the cusp height is less than the machining tolerance. The inclination angle λ by which the cutter is rotated about L Y, the yaw angle ω by which the cutter is rotated about L Z and the height δ by which the cutter is lifted along the normal of the surface are three variables used to build the 3D C-space. Next, the optimal cutter orientation is obtained in this corresponding 3D C-space via a special optimization process. The ideal 3D C-space set, the initial 3D C-space set and the objective function of the optimization process are based on machine tool kinematics. Boundary functions are determined by the geometry feature of the 3D C-space. The penalty function method is employed as the optimization method. In this paper, the cutting accuracy is self-guaranteed to be less than the machining tolerance. The cutting speed is set to be as high as possible based on optimal cutter orientation and maximized step-over distance.Keywords
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