Document Type : Research Paper

Author

Mechanical Engineering Department,Faculty of Technology, Batna 2 Universite, Fesdis-05000, Batna, Algeria

Abstract

In contour milling, to render the machining process more automated with significant productivity without remaining material after machining, a new recovery coefficient was developed. The coefficient was inserted in the computation of contour parallel tool paths to fix the radial depth of cut in the way to ensure an optimized overlap area between the passes in the corners, without residuals. Thus, this parameter, which has been earlier inserted by the user, is now being independent and is implemented automatically from the input data of the contour shape of the pocket. In order to prove the effectiveness of the present approach, a detailed comparison with the classical methods found in the literature we also performed. The results clearly show that the new method removes the residuals efficiently in an automatic way and minimizes the toolpath length respect to the other methods. Furthermore, this proposed approach can easily be worked on the actual machine tool.

Graphical Abstract

Automatic implementation of a new recovery coefficient for Reliable contour milling

Keywords

Main Subjects

[1] H. b. Liang, Y Z. Wang, and X. LI,“Implementation of an adaptive feed speed 3D NURBS interpolation algorithm”, Front. Mech. Eng, Vol. 1, No. 4, pp.403−408,(2006).
[2] R. QI, W. Liu, H. Bian, and L. Li,“Five-axis rough machining for impellers”, Front. Mech. Eng, Vol.4, No. 1, pp.71–76, (2009).
[3] F.Monies, I.Danis, C.Bes, S.Cafieri, andM.Mongeau, “A new machining strategy for roughing deep pockets of magnesium-rare earth alloys”, Int J. Adv. Manuf. Technol,Vol. 92, No. 9-12, pp.3883–3901, (2017).
[4] T. Fu, J. Zhao, and W. Liu,“Multi-objective optimization of cutting parameters in high-speed milling based on grey relational analysis coupled with principal component analysis”, Front. Mech. Eng, Vol. 7, No. 4, pp.445–452, (2012).
[5] C. K. Hyun, G. L. Sung, andY. Y.Min,“An optimized contour parallel tool path for 2D milling with flat end mill”, Int J. Adv. Manuf. Technol, Vol. 31, No. 5, pp.567–573, (2006).
[6] M. Dotcheva, K. Dotchev, and I. Popov, “Modeling and optimization of up and down milling processes for a representative pocket feature”, Int J. prec. Eng Manuf, Vol. 14, No. 5, pp.703–708, (2013).
[7] F. Y. Han, D. H. Zhang, M. Luo,and B. H. Wu, “Optimal CNC plunge cutter selection and tool path generation for multi-axis roughing free-form surface impeller channel”, Int J. Adv. Manuf. Technol, Vol. 71, No. 9, pp.1801–1810, (2014).
[8] S.Sui, Y.Li, W.Shao, and P. Feng, “Tool path generation and optimization method for pocket flank milling of aircraft structural parts based on the constraints of cutting force and dynamic characteristics of machine tools”, Int J. Adv. Manuf. Technol, Vol. 85, No. 5-8, pp.1553–1564, (2016).
[9] S. C. Parc, and Y. C. Chung, “Offset tool-path linking for pocket machining”, Computer Aided Design, Vol. 34, No. 4, pp. 299–308, (2002).
[10] S. C. Park, and B. K. Choi, “Tool-path planning for direction-parallel area milling”, Computer Aided Design, Vol. 32, No. 1, pp.17–25, (2000).
[11] C. Göloglu, and Y.Arslan, “Zigzag machining surface roughness modeling using evolutionary approach”, J Intell. Manuf, Vol. 20, No. 2, pp.203–210, (2009).
[12] P. Selvaraj, and P. Radhakrishnan, “Algorithm for Pocket Milling using Zig-zag Tool Path”, Defence Science Journal, Vol.56, No. 2, pp.117–127,(2006).
[13] S. C. Park,and B. K. Choi, “Uncut free pocketing tool-paths generation using pair-wise offset algorithm”, Computer Aided Des, Vol. 33, No. 10, pp.739–746, (2001).
[14] M.Held,“ Voronoi diagrams and offset curves of curvilinear polygons”, Computer Aided Design, Vol. 30, No. 4, pp.287–300,(1998).
[15] R. Ramamurthy, and R. T.Farouki,“ Voronoi diagram and medial axis algorithm for planar domains with curved boundaries”, Journal of Computational and Applied Mathematics, Vol. 102, No. 1, pp.253–277, (1999).
[16] B. K. Choi, S. C. Park, “A pair-wise offset algorithm for 2D point-sequence curve”, Computer Aided Design, Vol. 31, No. 12, pp.735–745,(1999).
[17] B. K. Choi, B. H. Kim,“Die-cavity pocketing via cutting simulation”, Computer Aided Design, Vol.29, No. 12, pp.837–846, (1997).
[18] C. K. Hyun, “Tool path modification for optimized pocket milling”, International Journal of Production Research, Vol. 45, No. 24, pp.5715–5729, (2007).
[19] A. Banerjee, H. Y. Feng, andE. V.Bordatchev,“ Process planning for Floor machining of 2½D pockets based on a morphed spiral tool path pattern”, Computers and Industrial Engineering, Vol. 63, No. 4, pp. 971–979, (2012).
[20] A. Abdullahil,“Selection of efficient cut pattern in simple pocket machining”, International Conference on Mechanical Engineering, Dhaka, Bangladesh, AM, , Vol. 79, pp. 1–6, (2007).
[21] M. Held, G. Lukacs, and L. Andor, “Pocket machining based on contour parallel tool paths generation by means of proximity maps”,Computer Aided Design, Vol. 26, No. 3, pp.189–203, (1994).
[22] S. Sui, Y. Li, W. Shao, andP. Feng, “Tool path generation and optimization method for pocket flank milling of aircraft structural parts based on the constraints of cutting force and dynamic characteristics of machine tools”, Int J. Adv. Manuf. Technol, Vol. 85, No. 5-8, pp.1553–1564, (2016).
[23] F. Monies, I. Danis, C. Bes, S. Cafieri, and M. Mongeau, “A new machining strategy for roughing deep pockets of magnesium-rare earth alloys”, International Journal of Advanced Manufacturing Technology, Vol. 92, No. 9-12, pp. 3883–3901, (2017).
[24] F. Y. Han, D. H. Zhang, M. Luo, and B. H. Wu,“Optimal CNC plunge cutter selection and toolpath generation for multi-axis roughing free-form surface impeller channel”, International Journal of Advanced Manufacturing Technology, Vol. 71, No. 9-12, pp. 1801–1810, (2014).
[25] S. C. Park, Y. C. Chungb, and B. K. Choi,“ Contour parallel offset machining without tool-retractions”, Computer Aided Design, Vol. 35, No. 9, pp.841–849, (2003).
[26] M. S. A. Mansor, S. Hinduja, and O.Owodunni,“ Voronoi diagram-based tool path compensations for removing uncut material in 2½D pocket machining”, Computer Aided Design, Vol. 38, No. 3, pp.194–209, (2006).
[27] H. S. Choy, and K. W.Chan,“A corner-looping based tool path for pocket milling”, Computer Aided Design, Vol. 35, No. 2, pp.155–166, (2003).
[28] Z. Y. Zhao, C. Y. Wang, H. M. Zhou, Z. Qin, “Pocketing toolpath optimization for sharp corners”, Journal of Materials Processing Technology, Vol. 192, No. 193, pp.175–180, (2007).
[29] M.Zhou, G.Zheng, and S. Chen,“ Identification and looping tool path generation for removing residual areas left by pocket roughing”, Int. J. Adv. Manuf. Technol, Vol. 87, No. 1-4, pp.765–778, (2016).
[30] Z. Lin, J Fu, H. Shen, and W. Gan,“ Global Uncut Regions Removal for Efficient Contour-Parallel Milling”, International Journal of Advanced Manufacturing Technology, Vol. 68, No. 5, pp.12411252, (2013).
[31] E. Bahloul, M. Brioua, and C. Rebiai,“An efficient contour parallel tool path generation for arbitrary pocket shape without uncut regions”, International Journal of Precision Engineering and Manufacturing, Vol. 16, No. 6, pp.1157–1169, (2015).
[32] H. Ramaswami, R. S. Shaw, and S. Anand,“Selection of optimal set of cutting tools for machining of polygonal pockets with islands”, Int J. Adv. Manuf. Technol, Vol.53, No. 9, pp.963977, (2011).
CAPTCHA Image