Development of CAM System Based on Simulation of the Copy Operation.

Abstract

For a high speed machining and a new type surface finishing with non-rotating cutting tools, it is necessary to develop a CAM system that can generate accurate CL data with high speed and high reliability. In order to extend CAM functions, a unified algorithm for CL data generation that can be applied for both rotating cutting tools and non-rotating ones was developed which is based on simulating the servo data generation method of a copy milling machine. The model and the stylus head are represented by a CSG data structure, and the tool path is defined in a calculation of contact points between the model and the stylus head, and normal vector at contact point. Therefore, preceding processes of offset surface generation and tool interference check can be abbreviated. The developed system has following four tool path modes; (1) the scanning line mode, (2) the contour line mode, (3) the 3D profile mode, (4) the contour line roughing mode. The contour line mode is suitable for high-speed machining because it will provide stable cutting with a small variation in cutting loads. Tool path simulations and cutting tests show that the developed CAM system can generate CL data of various types of tool path mode with high accuracy and reliability.