An accurate,efficient envelope approach to modeling the geometric deviation of the machined surface for a specific five-axis CNC machine tool |
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| Affiliation: | 1. Department of Mechanical and Industrial Engineering, Concordia University, Montreal, Canada H3G1M8;2. State Key Laboratory of Advanced Design and Manufacture for Vehicle Body, Hunan University, Changsha, Hunan 410082, China;1. Faculty of Mechanical Engineering and Management, Poznan University of Technology, 3 Piotrowo St., 60-965 Poznan, Poland;2. Faculty of Mechanical Engineering, University of Zielona Gora, 4 Prof. Z. Szafrana Street, 65-516 Zielona Gora, Poland,;3. Turbocharger Research Institute, University of Huddersfield, Huddersfield HD1 3DH, UK,;4. Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St., 45-758 Opole, Poland;1. Key Laboratory of Contemporary Design and Integrated Manufacturing Technology, Ministry of Education, Northwestern Polytechnical University, Xi’an 710072, China;2. Machining and Condition Monitoring Group, Faculty of Engineering, University of Nottingham, NG7 2RD, UK;1. The State Key Lab of Fluid Power Transmission and Control, College of Mechanical Engineering, Zhejiang University, Hangzhou 310027, China;2. Key Laboratory of 3D Printing Process and Equipment of Zhejiang Province, College of Mechanical Engineering, Zhejiang University, Hangzhou 310027, China;1. State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, PR China;2. Manufacturing Automation Laboratory, Department of Mechanical Engineering, The University of British Columbia, Vancouver, BC, V6T 1Z4, Canada;1. Department of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, PR China;2. Department of Mechanical and Industrial Engineering, Concordia University, Montreal, Quebec, Canada;1. The State Key Lab of Fluid Power Transmission and Control, college of Mechanical Engineering, Zhejiang University, Hangzhou 310027, China;2. Key Laboratory of 3D Printing Process and Equipment of Zhejiang Province, College of Mechanical Engineering, Zhejiang University, Hangzhou 310027, China;3. Kunshan Industrial Technology Research Institute Co., Ltd, Kunshan 215347, China |
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| Abstract: | Geometric deviation, defined as the difference between the nominal surface and the simulation model of the machined surface, is the fundamental concern of five-axis tool path planning. Since the machined surface is part of the cutter envelope surface generated by the cutter motion, it is necessary to calculate the envelope surface in order to obtain the geometric deviation. In the stage of tool path planning, current approaches calculate the cutter envelope surface by using the cutter motion along the given tool path. However, the cutter motion of practical machining on a specific five-axis CNC machine tool is different from the given tool path. Moreover, the computation is very challenging when the accurate cutter motion of practical machining is applied to calculate the envelope surface. To overcome these two problems, a geometric envelope approach with two major distinctions is proposed in this paper. First, the envelope surface of the cutter undergoing a general motion is efficiently obtained as a closed-form vector expression. Second, the accurate cutter motion, which is determined by machine kinematic and interpolation scheme in practical machining, can be easily applied to calculate the accurate envelope surface. With the envelope surface, the geometric deviation is calculated to estimate the overcut or undercut in five-axis milling. An example is given to demonstrate the validity of the proposed method. |
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| Keywords: | Envelop theory Envelope surface Five-axis CNC machining Milling Geometric deviation |
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