复杂多曲面高速铣3轴精加工刀轨优化算法

针对高速铣削的特点和现实要求,提出了适合高速铣削面向复杂曲面的3轴精加工可变行距的螺旋线与Zigzag混合刀轨优化算法．该算法生成的刀轨光顺简洁,满足了高速加工的要求．算法中采用的行间NURBS过渡边优化法和跨区域刀轨优化法,具有合理性和实用性．加工结果表明,加工表面无过切．经测试,算法稳定可靠．     

平面型腔广义转角残留区螺旋环刀轨计算算法

为清除平面复杂型腔粗加工后产生的多种不规则的残留区,提出一种螺旋环刀轨方案;在构建广义转角残留区的基础上,设计和建立统一的螺旋环刀轨生成算法,以满足顺铣和径向切深均匀的要求.首先引入广义转角残留区的概念,统一定义和表示转角、窄颈残留区;然后根据瓶颈线对窄颈残留区进行分区,构建广义转角残留区;最后依据径向切深,采用迭代的方法生成螺旋环刀轨.实例结果表明,该算法是正确和有效的.     

利用调和映射的复杂网格曲面螺旋刀轨生成算法

针对截平面法规划的复杂网格曲面刀轨的加工效率不高问题,提出一种复杂网格曲面螺旋刀轨生成算法.首先采用调和映射的方法对网格曲面进行参数化,然后根据残留高度确定参数网格中的参数环,在相邻参数环的参数点之间进行“分组匹配”,并依次计算初始和精确的对角参数螺旋线;在此基础上采用“区域划分”的方法快速生成了无干涉的网格曲面螺旋刀轨.对于复杂网格曲面的实验结果表明,文中的螺旋刀轨能够有效地提高截平面法刀轨的加工效率,且能够保证较好的加工质量.     

利用特征刀位点的三角网格表面NURBS刀轨生成

为了提高数控加工的加工效率和精度,提出一种利用特征刀位点的NURBS刀轨生成算法.采用截平面和三角网格模型的等距模型求交来计算直线刀轨的刀位点,由等距模型的顶点曲率估算刀位点处沿刀轨和刀轨间隔方向的曲率半径,并根据残留高度确定刀轨行距;对基于特征刀位点的NURBS曲线拟合算法进行改进,采用阈值分割的方法选取初始特征刀位点,采用相邻直线段夹角最大原则确定新特征点,并用刀位点的投影点参数对特征点参数进行修正.采用文中算法对直线刀轨的刀位点进行NURBS曲线拟合,并在刀轨行间采用NURBS曲线过渡,以减小数控程序量并提高刀轨光顺性.实验结果表明,文中算法效率高,采用其生成的刀轨具有较少的控制顶点、较高的拟合精度以及较好的光顺性.     

基于向量角分线的离散刀轨环子域分割算法

为提高环切加工刀轨质量及生成效率,提出一种基于向量角分线的二维截面轮廓子区域的分割算法.结合Voronoi图的全局分解思想,通过改进中轴线中对多边形凹顶点的不均等处理的拓扑结构,提出有效向量角分线的概念;通过判断向量角分线交点的属性来合并角分线,同时生成子域结点关系树,最终把离散刀轨环分割成隶属于每个边界元素的子区域,并在子区域基础上生成无自交的等距线.实验结果表明,该算法运行高效,可提高刀位轨迹生成的效率和质量,并改善产品的加工性能.     

三角网格表面等残留高度刀轨生成算法

针对截平面法规划的三角网格表面的刀轨长度较长、加工表面残留高度不均匀的问题,提出一种基于改进截平面法的等残留高度刀轨生成算法.首先在估算刀触点轨迹线垂直方向曲率半径的基础上,计算刀触点轨迹投影线并对其进行修正,去除其中冗余的投影点;然后由修正后的刀触点轨迹投影线构造驱动表面,利用驱动表面和网格表面迭代计算刀触点轨迹线;最后由刀触点轨迹线计算无干涉刀轨.与截平面法生成的刀轨进行比较分析的结果表明,文中算法生成的刀轨长度较小且获得的残留高度保持均匀,适合于三角网格表面表示的复杂表面的精加工.     

一个新的最大流问题增载轨算法

通过放松Ahujia和Orlin算法的约束，给出了一个新的增载轨算法．该算法实质上提供了一个构造、阻塞无环网络的策略，它可以在每次构造无环网络中得到更多的增载轨．从而进一步降低了找到每条增载轨的代价．实验表明，新的算法比Dinic算法快2～5倍，和目前实验性能最好的预流推进算法基本相近．说明增载轨类算法在实际性能方面未必落后于预流推进类算法．     

复杂曲面笔式加工的直接插补算法

复杂曲面笔式加工时的工具轨迹是位于曲面上的自由曲线轨迹．针对此类形式的轨迹，给出一种复杂曲面笔式加工时的自由曲线型刀轨的直接插补算法，即对位于曲面上以投影方式形成的任意自由曲线形式的刀轨进行插补计算，生成控制机床运动的指令．该方法的实现扩充了CNC系统的轨迹控制功能，提高了复杂曲面的加工效率．仿真和试切的结果证明算法可行而且有效．该算法也可以应用到整体曲面加工中．     

利用ABF++保角参数化的网格曲面刀轨规划

针对基于网格曲面参数化的刀轨规划中存在映射拉伸变形的问题,提出一种引入映射拉伸系数的网格曲面刀轨规划方法.首先采用ABF++保角参数化算法将网格曲面展平到参数域内;然后根据映射变形分析逐三角片地计算映射拉伸系数与梯度,并基于此将三维网格上的轨迹参数转换到参数网格上;最后根据参数域内的轨迹参数分别生成往复式刀轨与环形刀轨.以人脸模型为例进行了仿真与加工实验,验证了该方法的有效性.     

轮廓平移无跳刀连接刀路环树优化算法

提出一个无跳刀的轮廓平移刀路轨迹优化算法．根据刀路环之间父环和子环关系,提出“刀路环树”的概念,将加工刀路的一次环切定义为一个“刀路环向量”,并将刀路环的各个属性定义为刀路环向量的分量．根据无跳刀轨迹的要求,针对刀路环树的各个刀路环向量进行遍历,以获得了一个无跳刀的轮廓平移刀路轨迹算法,并通过与其他算法比较,证明该算法无跳刀、无重复切削,并且可以自动执行．     

Process planning for Floor machining of 2½D pockets based on a morphed spiral tool path pattern

This work proposes a process planning for machining of a Floor which is the most prominent elemental machining feature in a 2½D pocket. Traditionally, the process planning of 2½D pocket machining is posed as stand-alone problem involving either tool selection, tool path generation or machining parameter selection, resulting in sub-optimal plans. For this reason, the tool path generation and feed selection is proposed to be integrated with an objective of minimizing machining time under realistic cutting force constraints for given pocket geometry and cutting tool. A morphed spiral tool path consisting of G¹ continuous biarc and arc spline is proposed as a possible tool path generation strategy with the capability of handling islands in pocket geometry. Proposed tool path enables a constant feed rate and consistent cutting force during machining in typical commercial CNC machine tool. The constant feed selection is based on the tool path and cutting tool geometries as well as dynamic characteristics of mechanical structure of the machine tool to ensure optimal machining performance. The proposed tool path strategy is compared with those generated by commercial CAM software. The calculated tool path length and measured dry machining time show considerable advantage of the proposed tool path. For optimal machining parameter selection, the feed per tooth is iteratively optimized with a pre-calibrated cutting force model, under a cutting force constraint to avoid tool rupture. The optimization result shows around 32% and 40% potential improvement in productivity with one and two feed rate strategies respectively.     

Process planning for Floor machining of 2½D pockets based on a morphed spiral tool path pattern

This work proposes a process planning for machining of a Floor which is the most prominent elemental machining feature in a 2½D pocket. Traditionally, the process planning of 2½D pocket machining is posed as stand-alone problem involving either tool selection, tool path generation or machining parameter selection, resulting in sub-optimal plans. For this reason, the tool path generation and feed selection is proposed to be integrated with an objective of minimizing machining time under realistic cutting force constraints for given pocket geometry and cutting tool. A morphed spiral tool path consisting of G¹ continuous biarc and arc spline is proposed as a possible tool path generation strategy with the capability of handling islands in pocket geometry. Proposed tool path enables a constant feed rate and consistent cutting force during machining in typical commercial CNC machine tool. The constant feed selection is based on the tool path and cutting tool geometries as well as dynamic characteristics of mechanical structure of the machine tool to ensure optimal machining performance. The proposed tool path strategy is compared with those generated by commercial CAM software. The calculated tool path length and measured dry machining time show considerable advantage of the proposed tool path. For optimal machining parameter selection, the feed per tooth is iteratively optimized with a pre-calibrated cutting force model, under a cutting force constraint to avoid tool rupture. The optimization result shows around 32% and 40% potential improvement in productivity with one and two feed rate strategies respectively.     

Tool path generation for multi-axis freeform surface finishing with the LKH TSP solver

In freeform surface finishing, there are three major types of tool path topologies: the direction-parallel type, the contour–parallel type and the space-filling curve (SFC) type. The SFC topology is capable of covering the whole surface with only one path. In this paper, we present a new way of planning the SFC type tool path by formulating the planning task as a traveling salesman problem (TSP). The optimal path is generated in two steps. Firstly, a set of regular cutter contact (CC) points is generated on the input surface. A cutting simulation method is developed to evaluate the scallop error and determine the position of the next CC point in cross-feed direction. This method is free of local surface curvature assumptions and is therefore accurate for big cutters. Secondly, the obtained CC points are input into an efficient TSP solver LHK for the optimal CC point linking sequences. To stop the CC points from diagonal linking or penetrating linking, the Euclidean distance evaluation function for two CC points is redefined in LHK. The proposed tool path generation method is verified with several freeform surface examples; the results show that the method can automatically find the optimal feed direction and it can generate shorter tool path than the traditional SFC method. The feasibility of the proposed method is also verified by a cutting experiment.     

Heuristic and genetic approach for nesting of two-dimensional rectangular shaped parts with common cutting edge concept for laser cutting and profile blanking processes

This paper presents a novel two-dimensional nesting strategy suitable for sheet metal industries employing laser cutting and profile blanking processes. The proposed nesting approach is developed by the combination of heuristic and genetic algorithms in order to generate an effective nested pattern, in such a way that, it minimizes the sheet material wastage and also the cutting tool path distance, while arranging a set of rectangular parts in a rectangular sheet. With the proposed bottom–left heuristic method, at first, the parts are considered in a specific sequence and orientation, and each part is translated to the feasible bottom left most position on the previously placed parts and then adjusted to form the common cutting edges with adjacent parts. Further, the heuristic algorithm ensures the formation of clusters, in which a group of parts share the cutting edges, for effective handling of parts while cutting. Finally the optimal and effective nested pattern is generated by the genetic evaluation process which reproduces several sets of nested patterns, before converging to the optimality. The effectiveness of the proposed work, in terms of utilization of sheet material, is demonstrated by comparing the results obtained from the literature. Furthermore the uniqueness of the present approach in enhancing the nested pattern efficiency and minimizing the tool path distance with common cutting edge concept is illustrated.     

Mechanistic modelling of 5-axis milling using an adaptive and local depth buffer

A mechanistic model for 5-axis surface machining with a toroidal-end mill is presented in this work. A graphical representation of the tool movements is used to determine the in-process chip geometry and tool edge contact length using an adaptive and local depth buffer. The graphical representation of the tool movements is generated using either tooth swept sectors that model the tool’s cutting teeth as they rotate or the swept surface of the tool as it moves along the tool path. The mechanistic model was verified with two cutting experiments: The first cutting test showed that the data agrees with the simulation results within 7% of the peak-to-peak forces. The second cutting test modelled a more complex stock surface and tool path. The simulation results were within 10% of the measured peak-to-peak cutting torque.     

密集型多轮廓裁片的刀具空行程路径寻优

服装行业中缩短刀具裁剪空行程对于高效裁剪布料具有重要意义。结合服装裁片排列具有轮廓形状复杂、分布密集的特点,将问题转化成广义旅行商问题。 基于最大最小蚁群(MMAS)算法提出了一种新的用于裁片刀具空行程路径寻优的算法--密集多轮廓蚁群算法,该算法包括4步:1)用MMAS算法确定初步裁片顺序;2)由裁片顺序寻找各裁片入刀节点;3)将各裁片的入刀节点再次用MMAS进行顺序优化重组得到初步裁剪路径;4)反复迭代第2)步和第3)步以求得最优路径。实验验证了所提算法的有效性,对比现有的扫描算法以及双信息素蚁群(NACS)算法其结果分别提升了60.15%和22.44%,该算法在刀具空行程优化上具有明显优势。     

Modeling of cutting geometry and forces for 5-axis sculptured surface machining

5-Axis sculptured surface machining is simulated using discrete geometric models of the tool and workpiece to determine the tool contact area, and a discrete mechanistic model to estimate the cutting forces. An extended Z-buffer model represents the workpiece, while a discrete axial slice model represents the cutting tool. Determination of the contact area for a given tool move requires a swept envelope (SWE) of the tool path. The SWE is used to find the intersections of the tool envelope with Z-buffer elements (ZDVs) representing the workpiece. A 3-axis approximation of the 5-axis tool movement is used to simplify the calculations while maintaining a desired level of accuracy. The intersection of the SWE with each ZDV yields segments which are used to find the contact area between the cutter and the workpiece for a given tool path. The contact area is subsequently used with the discrete force model to calculate the vector cutting force acting on the tool.     

A Tool Path Generation Strategy for Sculptured Surfaces Machining

This paper presents a strategy to generate interference-free tool paths for machining sculptured surfaces. The strategy proposed here is first to determine the tool path topology. The values of the step length and the path interval are then calculated based on the machining tolerance requirements. After detecting and eliminating the tool interference, the interference-free tool path is generated. The effectiveness of the developed algorithm is demonstrated through simulation and actual cutting tests.     

A corner-looping based tool path for pocket milling

In milling around corners, cutting resistance rises momentarily due to an increase of cutter contact length. NC tool path generation in dealing with sharp corners thus requires special consideration. This paper describes an improved NC tool path pattern for pocket milling. The basic pattern of the improved tool path is a conventional contour-parallel tool path. Bow-like tool path segments are appended to the basic tool path at the corner positions. When reaching a corner, the cutter loops around the appended tool path segments so that corner material is removed progressively in several passes. By using the corner-looping based tool path, cutter contact length can be controlled by adjusting the number of appended tool path loops. The procedures of creating the improved tool path for different corner shapes are explained. The proposed tool path generation was implemented as an add-on user function in a CAD/CAM system. Cutting tests were conducted to demonstrate and verify the significance of the proposed method.     

A survey of interactive mesh‐cutting techniques and a new method for implementing generalized interactive mesh cutting using virtual tools‡

In our experience, mesh‐cutting methods can be distinguished by how their solutions address the following major issues: definition of the cut path, primitive removal and re‐meshing, number of new primitives created, when re‐meshing is performed, and representation of the cutting tool. Many researches have developed schemes for interactive mesh cutting with the goals of reducing the number of new primitives created, creating new primitives with good aspect ratios, avoiding a disconnected mesh structure between primitives in the cut path, and representing the path traversed by the tool as accurately as possible. The goal of this paper is to explain how, by using a very simple framework, one can build a generalized cutting scheme. This method allows for any arbitrary cut to be made within a virtual object, and can simulate cutting surface, layered surface or tetrahedral objects using a virtual scalpel, scissors, or loop cautery tool. This method has been implemented in a real‐time, haptic‐rate surgical simulation system allowing arbitrary cuts to be made on high‐resolution patient‐specific models. Published in 2002 by John Wiley & Sons, Ltd.