Tool Path Simulation Research Articles

Study on the Multi-Axis Machining Technology of Helical Gear

In view of characteristics of involute helical gear profile, analyzed the multi-axis machining process for helical gear. Focused on the processing characteristics of helical gear for multi-axis machining, discussed tool path generation, machining program, tool path simulation, cutter interference and collision detection for machine tool and gear profile, seeking out the optimal method and process of helical gear for multi-axis machining. Applying this machining technology in manufacture, it can improve performance of gear, while it can also improve efficiency of manufacture.

The Tool Space Trajectory and Stress Simulation of Manipulator Based on the Optimization Design

It’s not a difficult problem to accomplish mechanism designing of tool path. In order to meet the lightweight optimization design and the organization innovation for robot, cutting tool path optimization and simulation space, it still need further research. Firstly, using cutting tool of fruit picking robot, and doing kinematics analysis for displacement and velocity of the point on the edge of tool, a space curve motion equation was proposed; Secondly, through the analysis of sliding cutting theory, the sliding cutting angle was deduced, and the optimal way was determined; Thirdly, quantitative analysis was applied to analyze the affection of cutting quality caused by the cutting speed, and the optimal speed of blade was determined. Finally through the simulation and picking robot experiments, it was validated that the calculation model and the effectiveness of the curve track. The paper puts forward optimum tool’s space curve motion equation and sliding cutting angle, providing the theoretical support for lightweight optimization design of cutting mechanism of manipulator.

Tool Path Planning and Simulation for Five-Axis Machining Test

Tool Path Planning and Simulation for Five-Axis Machining Test

Realization of NURBS Surface CNC Machining Simulation in Matlab

This paper presents a method of realization of NURBS surface CNC Machining simulation in matlab, including NURBS surface production, tool path generation, discrete surface and simulation model construction and CNC machining simulation realization.

Development of machining technology for micropatterns with large surface area

With increasing demand for micropatterns such as V-shaped microgrooves and the trend of large surface areas in developing technologies, precision machining technology for micropatterns with large surface areas is expected to play an increasingly important role in today's manufacturing technology. In large-surface micromachining, machining time is much longer than that in general pattern machining and it is not easy to achieve uniform machining accuracy in the entire machined areas because of various factors. Therefore, systematic machining processes and technical development for achieving precision in each process are essential prerequisites to reduce the errors. In this study, we focused on developing machining technologies, which include a machine vision system for precise tool setting, an on-machine measurement system for large-area measurement, and software for tool path generation and simulation, for the fabrication of large-surface micropatterns in an electroless nickel-plated workpiece with single-crystal diamond tools and a 32-in., 675 × 450-mm mold with tens of V-and pyramid-shaped micropatterns.

Virtual workpiece: workpiece representation for material removal process

In this paper, an efficient methodology to generate a virtual workpiece (VWP) is presented. VWP is a workpiece in a virtual environment in which the geometric, kinematic, and thermo-mechanical effects of the process and resources can be reflected. VWP encompasses not only the macro-information corresponding to the shape of the “virtually” machined intermediate workpiece, but also the micro-information, such as the surface roughness, scallop heights, chatter mark, etc. To represent VWP, swept volume (SV) of geometrically defined cutters is generated first by envelope profiles which are calculated by the intersection of the Tool map with the Contact map of the tool moving direction. Then SV is tessellated to conduct elementary 1D Boolean subtraction of SVs from the IPW. The Boolean subtraction is realized by means of an efficient ray-triangle intersection test using Barycentric coordinates. Finally, VWP is reconstructed as a triangular mesh (STL, stereolithography data format) from the orthogonal triple-dexel model (TDM) which predicts machined surface quality, such as surface roughness, gouging and sharp edges and is reused for further operations, e.g., tool path generation, simulation and geometric metrology, etc. To demonstrate the validity of VWP modeling, several material removal processes, e.g., milling and micro-EDM operations, have been tested and the proposed approach has been proven to be applicable to enhance the quality of NC simulation and verification.

Development of an Integrated System of Geometric Modeling and Machining Simulation of End Mill

An integrated system of geometric modeling and machining simulation of end mills is presented for supporting end mill’s cutting analysis, structural optimization and digital manufacturing. In order to obtain accurate structural models, the main elements and detail features of end mills are modeled precisely, based on modular design and parametric design methodology. Through integrates 2D tool path and 3D virtual machining simulation seamlessly, a comprehensive simulation platform is constructed. To ensure the accuracy of manufacturing simulation model, the machining simulation model is compared to ideal design model. The results verify the correctness and rationality of the geometric modeling and machining simulation. NC codes generated by machining simulation can be output to tool grinder, supporting digital manufacturing of end mills.

A study on integrated design conjugation profiles application analysis of scroll profiles for automobile air conditioning

The research on scroll profiles theory at present mainly is aiming at the single profile and its amelioration or parameter optimization, not aiming at the natural characteristic of the profiles equation of scroll profiles itself. Thus, the intrinsic differential equation bearing on arc-length and tangent direction angle was studied. Using the inherent differential equation and general functional theory, the conversion ideas between the expression of intrinsic differential equation and the expression in Cartesian coordinate was studied, and the condition of involutes characteristic was presented. The detailed analysis of four typical scroll profiles was given. According to the four typical scroll profiles and based on the method of Taylor series, the unified formation of general functional integration scroll profiles was established, which perfected general theory of scroll profiles increasingly. The envelope method to seek conjugation engagement profiles was studied. The unified general functional equation of scroll profiles represented the admissible function scrolls and the conjugation engagement characteristic of which was studied. The engagement condition of conjugation scroll profiles and the expression in Cartesian coordinate of conjugation scroll profiles of general functional integration scroll profiles were educed. Therefore, the restriction of inherent characteristics of single scroll profiles model is broken through. Solid modeling and machine tool path simulation can bridge the gap between design and manufacture which is essential for the design and manufacture of scroll compressors. With this method a perfect solid model can be achieved, which leads to an optimal design in terms of quality, delivery time and cost. The presentation of unified formation of general functional integration scroll profiles represents foundation factor of instinct characteristics of scroll profiles, which widens the design method of scroll compressor for automobile air conditioning.

The Impeller Five-Axis NC Machining Simulation Based on UG NX 7.5

To improve the processing efficiency and Surface qualityof impeller. Impeller processing difficulties as a major object of study were researched by this paper. Using UG7.5 impeller processing module, Based on the impeller feature division idea and to optimize the impeller machining path.Finally, Through it carried out the tool path generation and simulation and verify the feasibility of processing. To effectively enhance programming efficiency and processing quality.

Tool path generation and simulation of dynamic cutting process for five-axis NC machining

Five-axis NC machining provides a valid and efficient way to manufacture the mechanical parts with complex shapes, which are widely used in aerospace, energy and national defense industries. Its technology innovations have attracted much attention in recent years. In this paper, the state-of-the-art techniques for five-axis machining process planning are summarized and the challenging problems are analyzed from the perspectives of tool path generation, integrated geometric/mechanistic simulation and machining stability analysis. The recent progresses in accessibility-based tool orientation optimization, cutter location (CL) planning for line contact and three-order point contact machining, shape control of cutter envelope surface and milling stability prediction are introduced in detail. Finally, the emerging trends and future challenges are briefly discussed.

Development of a virtual reality wire electrical discharge machining system for operation training

Wire electrical discharge machining (WEDM) uses a metallic thin wire to cut a programmed profile with high strength having sharp edges such as extrusion dies and blanking punches. However, the cost of purchasing and maintaining of WEDM equipment is very high for both the industry and general education institutions. Therefore, there are potential demands to reduce the expensive machine operation training cost, provide off-line collision-free simulation verification of the tool path, and examine the correctness of the programmed wire cutting NC codes. This paper presents the development of a virtual reality-based WEDM full machine simulation system which can emulate major functions of a real controller related to operation training and education. These functions include the tool path simulation, NC program interpretation and processing, kinematics of the machine mechanism, workpiece origin setting, etc. To demonstrate the developed system and illustrate the adopted method, the system capability is explained and shown in this paper. The research result can be used as a cost-effective interactive 3D digital tutoring system that has the benefits of improving on the inefficient, dangerous, and costly drawbacks in traditional learning and training for operating the real WEDM machine.

Chip form modelling and chip-forming animation in oblique cutting

The reliability of machining operation is an essential requirement in a modern production system. Chip control is one major aspect with regard to turning operation and becomes significant in industrial automation. At present, toolpath simulation is available in most computer aided manufacturing (CAM) systems. However, only the rendering scene of the stock material shape changing during cutting and the resultant part are shown. The chips formed in the machining process are not modelled or displayed in the simulation. To assess the chip control properly, many models and simulation methods were developed for predicting the chip forms produced in the cutting operation. If the chip forms can be predicted using some of the mathematical models, the design and planning of the machining operation can be greatly assisted, especially in the shop-floor level. Apart from chip form prediction, modelling of the machining process and chip formation are also issues that must be considered. To do this, a chip modelling and simulation system is proposed. Based on the machining parameters settings, the corresponding chip model can be calculated and simulated for more realistic analysis. The present paper first outlines the chip form mathematical model being used. The criteria to ensure that the theoretical model can be used to calculate the practical chip models effectively are described. Then the modelling of the chips and the simulation of the chip forming with computer graphic animation are explained. Several sets of turning parameters are used as examples to demonstrate how the corresponding chip models are calculated from the proposed system.

Computer-aided design and manufacturing of scroll compressors

Scroll type compressors have been becoming increasingly popular in refrigeration and air conditioning products due to their high efficiency, low noise, fewer components, low vibration, light weight and small size compared with other types of compressors. To design and manufacture scroll compressors, however, is not easy as their key parts have complex shapes with involute curves. A high degree of accuracy during assembly is required which brings difficulty into the manufacturing cycle. This paper presents the integrated approach of computer-aided design (CAD) and computer-aided manufacturing (CAM) for the design and manufacture of refrigeration scroll compressors. The approach is based on concurrent engineering and is implemented in Pro/ENGINEER software and Visual C++ programming. The work presented is focused on the integration of constructive solid geometry (CSG) solid modelling and CAM to effect the design of scroll compressors in particular. The involute scroll curve is created from equations. Designers can transfer the model to a manufacturing engineer for process planning, etc. The manufacturing engineer can also advise the designer if some revisions are needed and the model can even be evaluated through the Internet. Many experts can check the models and processes of design and manufacturing. Thus, solid modelling and machine tool path simulation can bridge the gap between design and manufacturing which is essential for concurrent engineering. With this approach a correct and precise solid model can be achieved, which leads to an optimal design in terms of quality, delivery time and cost. This work is essential for the manufacturing of the scroll components and their inspection on co-ordinate measuring machines (CMMs) during manufacture. This CAD/CAM system has a potential application to other complex mechanical components, as the approach is a generic one.

Extraction and Optimisation of Cutting Conditions for 21/2 -Axis Milling

To optimise an NC program, the first step is to understand the cutting conditions or parameters. Such cutting parameters as radial and axial depths of cut and material removal rate (MRR) are implied in the NC program. In this paper, for the commonly used 21/2-axis milling, a new technique for extracting the implicit cutting parameters from NC programs is proposed based on the tool path simulation, and a prototype is developed. Furthermore, an optimisation strategy of NC programs with the constant MRR is suggested, based on the extraction. The technique is different from previous ones in that 3D calculation is simplified to 1D, a huge memory is not needed and the calculation is extremely fast. It lays the foundation for the optimisation of NC programs and thus the improvement of productivity.

A three-dimensional CAD/CAM/CAE integration system of sculpture surface die for hollow cold extrusion

In this paper, a CAD/CAM/CAE integration system for a sculptured surface die for hollow cold extrusion has been developed by using C language for Windows. A sculptured surface model with variable control points is incorporated with a general three-dimensional velocity field to analyze the extrusion process. The profiles of the product and the billet are generated in the CAD module. The fitting points are generated to interpolate the profiles of the product and the billet. The initial guess of control points are created by using the offset of corresponding fitting points in the axial direction. The control points are varied automatically to obtain the optimum die surface by using the upper-bound method and optimization procedure. The CAM module generates the cutter locations by using the optimized die surface model. The gouging areas of the tool path are detected and removed. The calculated cutter locations are verified through the tool path simulation. The NC codes are generated automatically by using the gouging-free cutter locations and then sent directly to a three-axis CNC machine centre to manufacture the EDM electrodes. The extrusion die cavity is made by using an EDM process. Extrusion experiments have verified the proposed CAD/CAM/CAE integration system is successful.