Size Of Cutting Tool Research Articles

Cutter-path generation using multiple cutting-tool sizes for 2-1/2D pocket machining

Existing commercial CAD/CAM systems allow the user to generate the cutter-path for machining a 2-1/2D pocket by using only a single cutting-tool size. Therefore, to avoid potential problems, such as gouging and unmachined areas, the user tends to choose the size of the cutting-tool in a conservative manner. This can result in longer processing time and higher production cost than those that can be achieved by using multiple cutting-tool sizes to machine a given pocket. The key to cutter-path generation using multiple cutting-tool sizes lies in having an efficient mechanism for representing the material volumes that can be removed by a specified cutting-tool size and the unmachined material volumes that will remain after its use. In this paper, we develop a novel concept called the Voronoi mountain and describe its application to cutter-path generation using multiple cutting-tool sizes. The theoretical significance of this approach stems from its ability to: (i) to create a Voronoi mountain representation of unmachined material volumes without having to construct the corresponding Voronoi diagram; and (ii) to accommodate generalized pocket geometries.

Selection of an optimal set of cutting-tool sizes for 2 [formula omitted]D pocket machining

The availability of high speed automatic tool change mechanisms in modem CNC machining centers is making it practical to consider the use of multiple cutting-tool (specifically, flat end-mill) sizes to reduce the total time for machining a 2 1 2 D) pocket. However, current CAD/CAM systems do not support pocket machining using multiple cutting-tool sizes. In this paper, we describe a two-phase methodology for selecting an optimal set of cutting-tool sizes to machine a 2 1 2 D pocket. In the first phase, we employ a new concept called the Voronoi mountain in order to calculate the material volume that can be removed by a specific cutting-tool size, the material volume that will subsequently remain to be machined, and the cutter-paths (and corresponding processing times) for each cutting-tool. In the second phase, we apply a dynamic programming approach for optimal selection of cutting-tool sizes on the basis of the processing time. Our computational experiments indicate that substantial savings in processing time can be achieved by using multiple cutting-tool sizes to machine 2 1 2 D pockets.

Selection of an optimal set of cutting-tools for a general triangular pocket

The size(s) of the cutting-tool (end-mill) chosen for machining a given pocket has a significant impact on the machining time. However, the selection of cutting-tool sizes is typically based on human judgment and estimates, and is therefore prone to be conservative and non-optimal. The focus of this paper is on the development of a procedure for selection of an optimal set of cutting-tools for staircase milling of general triangular pockets with round corners, such that the machining time is minimized. We first derive analytical models for determining the time for machining the pocket using a given cutting-tool. Subsequently, we employ a dynamicprogramming based approach that utilizes these analytical models to determine the best set of cutting-tools, from the available inventory of cutting-tools, to machine the pocket. The proposed approach can be extended for optimal selection of cutting-tools for rough-machining of 3-D sculptured cavities.

Approximate methods for simulation and verification of numerically controlled machining programs

Algorithms for simulation and verification of Numerically Controlled (NC) machining programs are presented. Compared to NC simulation based on conventional solid modeling systems, these models are designed to give approximate results, but with a substantial decrease in computer time. The surfaces of the part are discretized into a Surface Point Set (SPS) with a point spacing dependent on cutting tool size and shape local surface curvature and the desired accuracy of the approximate simulation. The surface-surface intersection calculations of the solid modeling approach are replaced by the intersection of the surface of the tool movement envelope with straight lines emanating from the surface points. The methods are applicable to both 3 and 5 axis machining. Samples test cases are presented, and implementation and efficiency issues are discussed.

Methods for detecting errors in numerically controlled machining of sculptured surfaces

The numerically controlled (NC) machining of sculptured surfaces is an error-prone process often requiring several attempts before an error-free NC program is produced. A technique designed to move the NC proof process into software is described. The system outputs a color-coded graphics display of the machined surface that shows out-of-tolerance areas. To gain efficiency, surface curvature and cutting-tool size are used as inputs to a surface discretization algorithm, which guarantees that a user-defined level of simulation accuracy is achieved. The simulation time grows linearly in both desired accuracy and in the number of tool movements. In typical test cases, NC programs for complex automotive body panels were simulated and verified in CPU times that ranged between 5 and 30 minutes. >