Abstract
In the case of 2.5D rough milling operations, machining efficiency can significantly be increased by providing a uniform tool load. This is underpinned by the fact that uniform load has a positive effect on both tool life and machining time. Unfortunately, conventional contour-parallel tool paths are unable to guarantee uniform tool loads. However, nowadays there are some advanced path generation methods which can offer a constant tool load by controlling the cutter engagement angle. Yet, the spread of these non-equidistant offsetting methods is hindered by their dependence on complex calculations. As a solution to this problem, the Fast Constant Engagement Offsetting Method (FACEOM), developed in the scope of our previous study, is seen to be taking a step towards reducing computational needs. In this paper, suggestions for further improvements of FACEOM are presented. Decreasing the number of path points to be calculated is made possible by implementing adaptive step size and spline interpolation. Through simulation tests, it was also analysed which of the numerical methods utilized for solving boundary value problems can be applied to obtain the shortest calculation time during tool path generation. The practical applicability of the algorithm has been proved by cutting experiments. With respect to research results, this paper also describes how a tool path created by the algorithm can be adapted to controllers of CNC machine tools. Solutions presented in this paper can promote a wider application of a modern path generation method that ensures constant tool loads.
Highlights
Metal cutting technologies still assume great importance in part manufacturing [1]
It is worth mentioning that this paper focuses on 2.5D milling, the methods employed can be extended to five-axis machining, where the control of cutting force through cutter engagement is an essential area of research [45, 46]
It is advisable to set this value low, because this parameter will be needed and used only if it is not possible to generate the path. This can occur in two cases: (1) the shape of the contour does not allow for a constant cutter engagement, (2) the initial conditions are not properly selected
Summary
Metal cutting technologies still assume great importance in part manufacturing [1]. The associated cutting process is usually divided into several stages: roughing and smoothing steps are typically separated [2]. Their common shortcoming is that technological aspects, such as tool load and chip formation, are not taken into account [11] As a result, both cutting force and cutting temperature can sharply fluctuate in the case of conventional direction-parallel or contour-parallel strategies [12]. Cutting characteristics do not show any extreme fluctuations at trochoidal tool paths; Li et al have shown that even with this strategy, controlling the cutter engagement can increase machining efficiency [24]. It would be challenging to apply optimization procedures that require path re-generating several times with different settings Taking this into account, the method can indirectly help to increase production efficiency. Be extended to five-axis machining, where the control of cutting force through cutter engagement is an essential area of research [45, 46]
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