Title: Machining of complex sculptured surfaces with feed rate scheduling

Authors: Mustafa Kaymakci, Ismail Lazoglu, Yavuz Murtezaoglu

Addresses: Manufacturing Automation and Research Center, Department of Mechanical Engineering, Koc University, Sariyer, Istanbul, Turkey. ' Manufacturing Automation and Research Center, Department of Mechanical Engineering, Koc University, Sariyer, Istanbul, Turkey. ' ModuleWorks GmbH, Ritterstr, Aachen, Germany

Abstract: Machining of non-monotonic sculptured surfaces with minimum cycle times has been one of the major priorities in most of the industries. Reductions in machining times with optimised NC codes are also the targets of Computer-Aided Manufacturing (CAM) software packages developers. This target must be reached without violating the physical limits of the Computer Numerical Control (CNC) machines. This paper presents that the cutting forces for very complex sculptured surfaces can be precisely predicted. Therefore, rather than using conventional constant feed rate all along the tool path for sculptured surfaces, it is recommended to utilise the new Forced based Feed rate Scheduling (FFS) strategy. In FFS technique, the resultant cutting forces are aimed to be kept constant by varying the feed rate along the tool path. Simulations and experimental validations are performed for non-monotonic complex sculptured surfaces. It is shown that with the new FFS strategy the cycle times of sculptured surface machining are decreased significantly.

Keywords: ball end milling; computer-aided design; CAD; modelling; computer-aided manufacturing; CAM; cycle times; freeform surfaces; sculptured surfaces; CNC machining; cutting forces; feed rate scheduling; cycle time reduction.

DOI: 10.1504/IJMR.2006.011351

International Journal of Manufacturing Research, 2006 Vol.1 No.2, pp.157 - 175

Available online: 22 Nov 2006 *

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