Title: Process simulation and feedrate selection for three-axis sculptured surface machining

Authors: R.B. Jerard, B.K. Fussell, M. Xu, C. Yalcin

Addresses: Department of Mechanical Engineering, University of New Hampshire, Durham, NH, USA. ' Department of Mechanical Engineering, University of New Hampshire, Durham, NH, USA. ' Department of Mechanical Engineering, University of New Hampshire, Durham, NH, USA. ' Department of Mechanical Engineering, University of New Hampshire, Durham, NH, USA

Abstract: This research is focused on improving the efficiency of Computer Numerical Control (CNC) machining by enabling automatic feedrate selection. Model accuracy and utility are improved by a calibration process that uses spindle motor power and a wide variety of test cut geometries. A low-cost noninvasive spindle motor power sensor is combined with geometric and mechanistic models of the cutting process. Different constraints are set for rough, semi-finish and finish passes. A Numerical Control (NC) part program is processed one tool move at a time by the feedrate selection planner. For each tool move, a geometric model calculates the cut geometry. The selection algorithm then chooses the fastest possible feedrate, subject to constraints on part quality, tool health and machine tool capabilities. Experimental results for a sculptured surface bottle mould show the value of the method as an aid to process planning.

Keywords: constraints; feedrate selection; geometric modelling; optimisation; process planning; sculptured surfaces; process simulation; CNC machining; machining efficiency; calibration; spindle motor power; NC part programming.

DOI: 10.1504/IJMR.2006.011350

International Journal of Manufacturing Research, 2006 Vol.1 No.2, pp.136 - 156

Available online: 22 Nov 2006 *

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