Title: Improving free form surface machining performance by ball end milling model

Authors: A.C. Manav, E. Akgun, I. Lazoglu

Addresses: Manufacturing and Automation Research Center, Koc University, Mechanical Engineering Department, Sariyer, Istanbul 344540, Turkey. ' Manufacturing and Automation Research Center, Koc University, Mechanical Engineering Department, Sariyer, Istanbul 344540, Turkey. ' Manufacturing and Automation Research Center, Koc University, Mechanical Engineering Department, Sariyer, Istanbul 344540, Turkey

Abstract: In CNC (computer numerical control) programs, cutting tool needs to move along a path described by a sequence of curves starting from the predefined Cutter Location (CL) points. In this article, cycle time is minimised and cutting forces are limited by a threshold for toolpath generation. In order to determine the cutting forces in each direction for all CL points a force map which overlapping with a uniform Cartesian mesh is constructed showing all possible cutting forces from each CL point to its neighbours. This map is obtained by pre-computation of force simulations in each direction. Force simulation of the newly developed paths and its experimental validation are obtained and compared. Moreover, forced-based feedrate scheduling strategy is utilised for the same free form surface to decrease cycle time. Feedrate is adjusted along toolpath to keep cutting forces at preset force value.

Keywords: design engineering; computer numerical control; CNC tool paths; toolpath generation; force based feedrate scheduling; milling force; freeform surfaces; surface machining; ball end milling; modelling; simulation.

DOI: 10.1504/IJDE.2008.024791

International Journal of Design Engineering, 2008 Vol.1 No.4, pp.434 - 444

Published online: 30 Apr 2009 *

Full-text access for editors Access for subscribers Purchase this article Comment on this article