A physically-based model for global collision avoidance in 5-axis point milling |
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| Affiliation: | 1. Mechanical, Materials and Aerospace Engineering Department, Illinois Institute of Technology, Chicago, IL 60616, United States;2. Department of Mechanical Engineering, The University of Wisconsin-Madison, Madison, WI 53706, United States;1. Department of Industrial Engineering and Engineering Management, National Tsing-Hua University, Hsinchu, Taiwan;2. State Key Lab of Digital Manufacturing Equipment & Technology, Huazhong University of Science & Technology, Wuhan, China;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. School of Computer Science and Technology, Harbin Institute of Technology, West Wenhua Str. 2, 264209 Weihai, China;2. BCAM – Basque Center for Applied Mathematics, Alameda de Mazarredo 14, 48009 Bilbao, Basque Country, Spain;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. School of Mechanical Engineering and Automation, Beihang University, Beijing 100191, People’s Republic of China;2. School of Mechanical Engineering, Shandong University of Technology, Zibo 255049, People’s Republic of China |
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| Abstract: | Although 5-axis free form surface machining is commonly proposed in CAD/CAM software, several issues still need to be addressed and especially collision avoidance between the tool and the part. Indeed, advanced user skills are often required to define smooth tool axis orientations along the tool path in high speed machining. In the literature, the problem of collision avoidance is mainly treated as an iterative process based on local and global collision tests with a geometrical method. In this paper, an innovative method based on physical modeling is used to generate 5-axis collision-free smooth tool paths. In the proposed approach, the ball-end tool is considered as a rigid body moving in the 3D space on which repulsive forces, deriving from a scalar potential field attached to the check surfaces, and attractive forces are acting. A study of the check surface tessellation is carried out to ensure smooth variations of the tool axis orientation. The proposed algorithm is applied to open pocket parts such as an impeller to emphasize the effectiveness of this method to avoid collision. |
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| Keywords: | 5-axis machining Collision-free Potential field Tool path generation Ball-end milling |
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