Korean Journal of Computational Design and Engineering (한국CDE학회논문집)

Society for Computational Design and Engineering (한국CDE학회)
권호 표지

Optimal Tool Length Computation of NC Data for 5-axis Ball-ended Milling

5축 볼엔드밀 가공 NC 데이터의 최적 공구 길이 계산

  • 조현욱 (영남대학교 대학원 기계공학과) ;
  • 박정환 (영남대학교 기계공학부)
  • Received : 2010.04.01
  • Accepted : 2010.08.24
  • Published : 2010.10.01
Download PDF
⟨ Previous Next ⟩

Abstract

The paper presents an efficient computation of optimal tool length for 5-axis mold & die machining. The implemented procedure processes an NC file as an initial input, where the NC data is generated by another commercial CAM system. A commercial CAM system generates 5-axis machining NC data which, in its own way, is optimal based on pre-defined machining condition such as tool-path pattern, tool-axis control via inclination angles, etc. The proper tool-length should also be provided. The tool-length should be as small as possible in order to enhance machinability as well as surface finish. A feasible tool-length at each NC block can be obtained by checking interference between workpiece and tool components, usually when the tool-axis is not modified at this stage for most CAM systems. Then the minimum feasible tool-length for an NC file consisting of N blocks is the maximum of N tool-length values. However, it can be noted that slight modification of tool-axis at each block may reduce the minimum feasible tool-length in mold & die machining. This approach can effectively be applied in machining feature regions such as steep wall or deep cavity. It has been implemented and is used at a molding die manufacturing company in Korea.

Keywords

References

  1. Mason, F., "5$\times$5 for High-productivity Airfoil Milling", American Machinist, Nov., pp. 37-39, 1991.
  2. Tonshoff, H. K. and Hemaadex-Camacho, J., "Die Manufacturing by 5-and 3-axis Milling", Mechanical Working Technology, Vol. 20, pp. 105-119, 1989. https://doi.org/10.1016/0378-3804(89)90022-3
  3. Hopkin, B., "Benefits of Positional Five-axis Machining", Moldmacking Technology, May 2005.
  4. Prosenjit Gupta, Ravi Janardan, Jayanth Majhi, and Tony Woo, "Efficient Geometric Algorithms for Workpiece Orientation in 4 and 5-axis NC Machining", Computer-Aided Design, Vol. 28, No.8, pp. 577-587, 1996. https://doi.org/10.1016/0010-4485(95)00071-2
  5. Jianhua Fan and Alan Ball, "Quadric Method for Cutter Orientation in Five-axis Sculptured Surface Machining", International Journal of Machine Tools & Manufacture, Vol. 48, pp. 788-801, 2008. https://doi.org/10.1016/j.ijmachtools.2007.12.004
  6. Tang, K., Chen, L.-L. and Chou, S.-Y., "Optimal Workpiece Setups for 4-axis Numerical Control Machining Based on Machinability", Computers in Industry, Vol. 37, pp. 27-41, 1998. https://doi.org/10.1016/S0166-3615(98)00067-0
  7. Takata, S., Tsai, M. D. and Inui, M., "A Cutting Simulation System for Machinability Evaluation Using a Workpiece Model", Annals of the CIRP, Vol. 38, pp. 417-420, 1989. https://doi.org/10.1016/S0007-8506(07)62736-X
  8. Hool, T. V., "Real Time Shaded NC Milling Display", Computer Graphics, Vol. 20, No.4, pp. 15-20, 1986. https://doi.org/10.1145/15886.15887
  9. Park, J-W. and Lee, J-G, "5-axis Machining; Cspace (Configuration Space) ; Effective Radius; Optimal Tool Position", Journal of the Korean Society of CAD/CAM Engineers, Vol. 7, No.1, pp. 34-41,2002.
  10. Kang, I.-S., Kim, J-S., Kim, S.-W. and Lee, K.Y, "The Characteristics of Cutting Force and Surface Roughness According to Tool Tilting Angle in 5axis High Speed Machining of Molds", Transactions of the Korean Society of Machine Tool Engineers, Vol. 16, No.5, pp. 63-69, 2007.
  11. Kang, J.-G., "Interference-Free Tool Path with High Machinability for 4- and 5-axis NC Machining of Free-Formed Surface", Journal of the Korean Society of Precision Engineering, Vol. 15, No.2 pp. 146-153, 1998.
  12. Lee, J.-G., Yang, S.-J and Park, J-W., "Setup Data Generation for Position 5-axis Machining of Die and Mold", Journal of the Korean Society of CAD/ CAM Engineers, Vol. 13, No.5, pp. 382-390, 2008.
  13. Kim, S. J, "NC Milling Productivity Incensement by Short Milling Tool Setting Method", Journal of the Korean Society for Precision Engineering, Vol. 25, No.5, May 2008.
  14. Delcam Korea, http:\\www.delcam.co.kr
  15. Cubictek, http:\\www.cubictek.com
  16. Castagnetti, C., Due, E. and Ray, P., "The Domain of Admissible Orientation Concept: A New Method for Five-Axis Tool Path Optimisation", Computer-Aided Design, Vol. 40, pp. 938-950, 2008. https://doi.org/10.1016/j.cad.2008.07.002
  17. Jun, C.-S., Cha, K. D. and Lee, Y-S., "Optimal Tool Orientations for 5-Axis Machining by Configuration-Space Search Method", Computer-Aided Design, Vol. 35, pp. 549-566, 2003. https://doi.org/10.1016/S0010-4485(02)00077-5
  18. Lim, T.-S., Lee, C.-M., Kim, S.W and Lee, D.-W., "Evaluation of Cutter Orientations in 5-Axis High Speed Milling of Turbine Blade", Journal of Materials Processing Technology 130-131, pp. 401-406, 2002. https://doi.org/10.1016/S0924-0136(02)00745-8
  19. Park, J-W., "Tool-path Generation for 5-axis Machining", Journal of the Korean Society of Precision Engineering, Vol. 26, No. 10, pp. 18-24, 2009.