Towards efficient 5-axis flank CNC machining of free-form surfaces via fitting envelopes of surfaces of revolution |
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| Affiliation: | 1. School of Computer Science and Technology, Harbin Institute of Technology, West Wenhua Street 2, 264209 Weihai, China;2. BCAM — Basque Center for Applied Mathematics, Alameda de Mazarredo 14, 48009 Bilbao, Basque Country, Spain;3. ModuleWorks GmbH, Henricistr. 50, 52072 Aachen, Germany;4. Center for Geometry and Computational Design, Vienna University of Technology, Wiedner Hauptstr. 8-10/104, A-1040 Vienna, Austria;1. Department of Computer Science, Technion, Israel;2. King Abdullah University of Science and Technology, Saudi Arabia;3. Institute of Discrete Mathematics and Geometry, TU Wien, Austria;1. The University of British Columbia, Department of Mechanical Engineering, Manufacturing Automation Laboratory, 2054-6250 Applied Science Lane, Vancouver, BC V6T 1Z4, Canada;2. State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, 800 Dong Chuan Road, Shanghai 200240, PR China;1. Department of Mechanical and Automation Engineering, The Chinese University of Hong Kong, Shatin, N.T., Hong Kong;2. Department of Computer Science, The Technion Israel Institute of Technology, Haifa 32000, Israel;1. School of Mechanical and Power Engineering, Henan Polytechnic University, Jiaozuo 454150, China;2. Key Laboratory for Precision and Non-Traditional Machining Technology of the Ministry of Education, Dalian University of Technology, Dalian 116024, China;3. School of Survey & Land Information Engineering, Henan Polytechnic University, Jiaozuo 454000, China |
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| Abstract: | We introduce a new method that approximates free-form surfaces by envelopes of one-parameter motions of surfaces of revolution. In the context of 5-axis computer numerically controlled (CNC) machining, we propose a flank machining methodology which is a preferable scallop-free scenario when the milling tool and the machined free-form surface meet tangentially along a smooth curve. We seek both an optimal shape of the milling tool as well as its optimal path in 3D space and propose an optimization based framework where these entities are the unknowns. We propose two initialization strategies where the first one requires a user’s intervention only by setting the initial position of the milling tool while the second one enables to prescribe a preferable tool-path. We present several examples showing that the proposed method recovers exact envelopes, including semi-envelopes and incomplete data, and for general free-form objects it detects envelope sub-patches. |
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| Keywords: | 5-axis CNC machining Flank milling Free-form surface Tangential movability Shape manufacturing |
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