Abstract
This paper presents a new method to calculate path scallop height of toroidal cutter during free-form surface machining in five-axis milling. The scallop height was defined as the distance between the tool intersection point and the normal point on the part surface. The tool intersection point was determined analytically by implementing the grazing method to define the swept curve of toroidal cutter. Meanwhile the normal surface on the part surface was determined using a hybrid analytical and discrete based methodology. The part surface was discretized by a number of normal vectors, then, they were used for defining the part surface mathematically. In this study, the effect of helical angle of cutting edge was taken into consideration in the model development. The proposed model was successfully used to generate the path scallop data for two model parts with free-form surface profiles. The effect of helical angle to the scallop height was also tested and the results showed that the helical angle tends to decrease the scallop height. The verification test to check the accuracy of the proposed method was performed and the results proved that the method was accurate.
Highlights
In milling operation, there are three parameters that are commonly used to define the quality of the machined surface: 1) machining tolerance, 2) scallop height, and 3) surface roughness
This paper presents a hybrid method to calculate the scallop height produced by a toroidal cutter during a free-form part surface
The Grazing Toroidal Approximation (GTA) is applicable to calculate the scallop height of helical toroidal cutter in five-axis milling process
Summary
There are three parameters that are commonly used to define the quality of the machined surface: 1) machining tolerance, 2) scallop height, and 3) surface roughness. The shape of swept curves of inclined flat and ball end mill, which are projected into 2D, can be precisely determined by parametric equation of ellipse curve This approach is not applicable to toroidal cutter. Determining the swept curve when the inclination angle exists becomes much more compli– cated To overcome such problem, Kiswanto et al [6] developed an analytical method, which is called grazing method, to define the swept curve of an inclined toroidal cutter. Kiswanto et al [6] developed an analytical method, which is called grazing method, to define the swept curve of an inclined toroidal cutter This method was proven effective to calculate cutter workpiece engagement in five-axis milling. The effect of helical angle was taken into consideration in the model development
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