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Optimal five-axis tool path generation algorithm based on double scalar fields for freeform surfaces

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Abstract

In order to generate efficient tool path with given precision requirements, scallop height should be kept under a given limit, while the tool path should be as short as possible to reduce machining time. Traditional methods generate CC curves one by one, which makes the final tool path far from being globally optimal. This paper presents an optimal tool path generation model for a ball-end tool which strives to globally optimize a tool path with various objectives and constraints. Two scalar functions are constructed over the part surface to represent the path intervals and the feedrate (with directions). Using the finite element method (FEM), the tool path length minimization model and the machining time minimization model are solved numerically. The proposed method is also suitable for tool path generation on mesh surfaces. Simulation results show that the generated tool path can be direction parallel or contour parallel with different boundary conditions. Compared to most of the conventional tool path generation methods, the proposed method is able to generate more effective tool paths due to the global optimization strategy.

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Abbreviations

S(u,v):

Part surface

C,C k :

CC curve

{T,N,B}:

Local frame along CC curve

ϕ 1 :

Number index function of CC curves

ϕ 2 :

Feedrate scalar function

w :

Tool path interval

r :

Ball-end mill radius

h :

Cusp height limit

κ B :

Normal curvature in direction

B I I,I I t :

Curvature tensor

F m a x :

Feedrate limit

A m a x :

Acceleration limit

x 1,x 2,⋯ ,x N :

Triangular mesh vertices

f 1,f 2,⋯ ,f M :

Triangular mesh faces

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Authors and Affiliations

  1. Department of Mechanical and Aerospace Engineering, The Hong Kong University of Science and Technology, Hong Kong, Hong Kong

    Ke Zhang & Kai Tang

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  1. Ke Zhang
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  2. Kai Tang
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Correspondence to Kai Tang.

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Zhang, K., Tang, K. Optimal five-axis tool path generation algorithm based on double scalar fields for freeform surfaces. Int J Adv Manuf Technol 83, 1503–1514 (2016). https://doi.org/10.1007/s00170-015-7646-5

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  • DOI: https://doi.org/10.1007/s00170-015-7646-5

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