• International Journal of CAD/CAM
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• v.5 no.1
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• pp.1-10
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• 2005

A new approach based on vector field clustering for tool path optimization of 5-axis CNC machining is presented in this paper. The strategy of the approach is to produce an efficient tool path with respect to the optimal cutting direction vector field. The optimal cutting direction maximizes the machining strip width. We use the normalized cut clustering technique to partition the vector field into clusters. The spiral and the zigzag patterns are then applied to generate tool path on the clusters. The iso-scallop method is used for calculating the tool path. Finally, our numerical examples and real cutting experiment show that the tool path generated by the proposed method is more efficient than the tool path generated by the traditional iso-parametric method.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.3
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• pp.63-70
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• 2020

Two rotational motions of the 5-axis machine tool maximize the degree of freedom of the tool axis vector, which improves tool accessibility; however, this lowers feed speed and rigidity, which impairs machining stability. In addition, cutting efficiency is lowered when compared with a flat end mill because typically, the ball-end mill is used when machining by rotational motion. This study increased cutting efficiency by using a corner radius flat end mill during impeller roughing. Furthermore, we proposed a fixed controlled machining of the rotary motion using geometric shape information to improve the feed speed and machining stability. Finally, we proposed a finishing tool path generation method using a vector net to increase the convenience and practicality of tool path generation. To verify its effectiveness, we compared the machining time, shape accuracy, and surface quality of the proposed method and an existing dedicated module.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2010.11a
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• pp.157-158
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• 2010

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.895-898
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• 2003

The higher precision is demanded in modem manufacturing and it requires the more accurate servo controller. Cross-coupling control (CCC) has been developed to improve contouring motion. In this paper we introduce a new nonlinear CCC that is based on contour-error-vector using a parametric curve interpolator. A vector from the actual tool position to the nearest point on the desire path is directly adopted. The contour-error-vector is determined by constructing a tangential vector of nearest point on desired curve and determining the vector perpendicular to this tangential vector from the actual tool position. Moreover, the vector CCC can apply directly and easily to free-form curves include convex and concave form. The experimental results on a three-axis CNC machine center show that the present approach significantly improves motion accuracy in multi-axis motion

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.8
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• pp.2012-2022
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• 1993

For the machining of the sculptured surfaces on 5-axis CNC milling machine, the milling cutter direction vector was determined in the study (I) with 5-axis post-processing. Thus, it was possible to cut the sculptured surfaces on five-axis CNC milling machine with the end mill cutter. Then, for smooth machined surfaces in five-axis machining of free-from surfaces, this study develops an algorithm for prediction of cusp heights. Also, it generates tool path such that the cusp heights are constrained to a constant value or under a certain value. For prediction of the cusp height between two basis points, a common plane, containing the line crossing two basis points and the summation vector of two normal vectors at two basis points, is defined. The cusp height is the maximum value of scallops on the common plane after end mill cutter passes through the common plane. Sculptured surfaces were machined with CINCINNATI MILACRON 5-axis machining center, model 20V-80, using end mill cutter. Cusp heights were verified by 3-dimensional measuring machine with laser scanner, WEGU Messtechnik GmbH.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.4
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• pp.64-71
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• 2004

The growing need for higher precision and productivity in manufacturing industry has lead to an increased interest in computer numerical control (CNC) systems. It is well known fact that the cross-coupling controller (CCC) is an effective method for contouring applications. In this paper, a multi-axis contour error controller (CEC) based on a contour error vector using parametric curve interpolator is introduced. The contour error vector is a vector from the actual tool position to the nearest point on the desired path. The contour error vector is the closest error model to the contour error. The simulation results show that the CEC is more accurate than the conventional CCC for a biaxial motion system. In addition, the experimental results on 3-axis motion system show that the CEC is simply applied to 3-axis motions and contouring accuracy is significantly improved.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.11
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• pp.1917-1924
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• 2003

This paper proposes a roughing path generation method fer machining impeller with 5-axis machining center. Traditional researches are focus on finishing for machining impeller. To achieve efficient machining, roughing method must be studied. The proposed method consists two steps : One is to select optimal tool size and tool attitude by dividing cutting area into two regions to reduce cutting time. The regions are automatically divided by character point on the geometry of impeller blade. After dividing, the tool of the optimal size is selected for each divided region. The other is avoidance of tool interference. Tool interference in cutting areas is avoided by checking the distance between tool axis vector and ruling line on blade surface or approximated plan between ruling line. Using this method, the cutting time is reduced efficiently.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.8
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• pp.2001-2011
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• 1993

This study deals with the machining of sculptured surfaces on 5-axis CNC milling machine with end mill cutter. The study (I) has the following contents. In 5-axis CNC milling, CL-data consist of CC-data and cutter axis direction vector at the CC-point. Thus, in machining of the sculptured surface on 5-axis CNC milling machine, determination of the direction vector of the milling cutter is very important. The direction vector is obtained by the fact that bottom plane of the milling cutter must not interfere with the free-form surface being machined. The interference is checked by the z-map method which can be applied in all geometric types of the sculptured surfaces. After generating NC part programs from 5-axis post-processing algorithms, sculptured surfaces were machined with 5-axis CNC milling machine (CINCINNATI MILACRON, 20V-80). From these machining tests, it was shown that the machining of the free-form surfaces on 5-axis CNC milling machine with the end mill has smaller cusp heights and shorter cutting time than on 3-axis CNC milling machine with the ball-end mill. Thus, 5-axis CNC end milling was effective machining method for sculptured surfaces. The study (II) deals with the prediction of cusp height and the determination of tool path interval for the 5-axis machining of sculptured surfaces on the basis of study(I).

• Journal of the Korean Society for Precision Engineering
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• v.13 no.1
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• pp.98-107
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• 1996

The use of composite hyperpatch model is proposed to predict a machine tool positional error over the entire work space. This is an appropriate representation of the distorted work space. This model is valid for any configuration of 3-axis machine tool. Tool position, which is given NC data or CL data, contains error vector in actual work space. In this study, off-line compensation scheme was investigated for tool position error due to inaccuracy in machine tool structure. The error vector in actual work space is corrected by the error model using Newton-Raphson method. The proposed error compensation method shows the possibility of improving machine accuracy at a low cost.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.10 no.2
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• pp.9-15
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• 2011

In order to develop a practical postprocessor for 5-axis machining, the general equations of numerically controlled (NC) data for 5-axis configurations with not only non-orthogonal rotary axes but also orthogonal rotary axes were exactly expressed by the inverse kinematics, and a Windows-based postprocessor written in Visual Basic was developed according to the proposed algorithm. The developed postprocessor is a general system that suitable for all kinds of 5-axis machine tool with orthogonal and non-orthogonal rotary axes. Through implementation of the developed postprocessor and verification by a cutting simulation and machining experiment, the effectiveness of the proposed algorithm is confirmed. Compatibility is improved by allowing exchange of data formats such as rotational tool center position (RTCP) controlled NC data, vector post NC data, and program object file (POF) cutter location (CL)data, and convenience is increased by adding the function of work-piece origin offset. Consequently, the technology of practical post-processor for 5-axis machining is developed.