Incomplete mesh-based tool path generation for optimum zigzag milling |
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Authors: | Hyun-Chul Kim Min-Yang Yang |
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Affiliation: | (1) Department of Mechanical Engineering, Korea Advanced Institute of Science and Technology, 305-701 Daejeon, South Korea |
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Abstract: | The majority of mechanical parts are manufactured by milling machines. Hence, geometrically efficient algorithms for tool
path generation and physical considerations for better machining productivity with guarantee of machining safety are the most
important issues in milling tasks. In this paper, we present an optimized path-generation algorithm for zigzag milling, which
is commonly used in the roughing stage as well as in the finishing stage, based on an incomplete two-manifold mesh model,
namely, an inexact polyhedron that is widely used in recent commercialized CAM software systems. First of all, a geometrically
efficient tool path generation algorithm using an intersection points-graph is introduced. Although the tool path obtained
from geometric information has been successful to make a desirable shape, it seldom considers physical process concerns like
cutting forces and chatter. In order to cope with these problems, an optimized tool path that maintains constant MRR in order
to achieve constant cutting forces and to avoid chatter vibrations at all times is introduced and the result is verified.
Additional tool path segments are appended to the basic tool path by using a pixel-based simulation technique. The algorithm
was implemented for two-dimensional contiguous end-milling operations with flat end mills and cutting tests were conducted
by measuring the spindle current, (which reflect machining situations) to verify the significance of the proposed method. |
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Keywords: | 2 5D milling Contour parallel tool path Constant cutting force Material removal rate |
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