Conventional tool-path generation strategies are readily available to generate geometrically feasible trajectories. Such approaches seldom take into consideration physical process concerns or dynamic system limitations. In the present work, an approach for improving a geometrically feasible tool-path trajectory based on quantifiable process metrics is developed. Two specific measures of toolpath quality are incorporated into the iterative improvement algorithm: instantaneous path curvature and instantaneous cutter engagement. These metrics are motivated by a desire to minimize acceleration requirements and maintain a stable steady-state cutting process during high-speed machining. The algorithm has been implemented for two-dimensional contiguous end-milling operations with flat end-mills, and case studies are presented to illustrate the approach.
Issue Section:
Technical Papers
1.
Zelinski, P., 1999, “Boeing’s One Part Harmony,” MMS Online, August 1999, http://www.mmsonline.com/articles/089903.html.
2.
Fallbo¨hmer
, P.
, Altan
, T.
, To¨nshoff
, H.
, and Nakagawa
, T.
, 1996
, “Survey of the Die and Mold Manufacturing Industry
,” J. Mater. Process. Technol.
, 59
, pp. 158
–168
.3.
Dews
, R. C.
, and Aspinwall
, D. K.
, 1997
, “A Review of Ultra High Speed Milling of Hardened Steels
,” J. Mater. Process. Technol.
, 69
, pp. 1
–17
.4.
Gough
, J.
, 1990
, “High Speed Machining for Toolmaking Applications
,” Precision Toolmakers
, 8
(3
), p. 154
154
.5.
Allock
, A.
, 1994
, “Fast-Moving Metal Removal Sets the Pace
,” Machinery and Production Engineering
, 152
, pp. 43
–48
.6.
Tlusty
, J.
, Smith
, S.
, and Winfough
, W. R.
, 1996
, “Techniques for the Use of Long Slender End Mills in High-Speed Milling
,” Annals of the CIRP
, 45
(1
), pp. 539
–559
.7.
Altintas
, Y.
, and Budak
, E.
, 1995
, “Analytical Prediction of Stability Lobes in Milling
,” Annals of the CIRP
, 45
(1
), pp. 357
–362
.8.
Davies
, M. A.
, Dutterer
, B.
, Pratt
, J. R.
, and Schaut
, A. J.
, 1998
, “On the Dynamics of High-Speed Milling With Long-Slender Endmills
,” Annals of the CIRP
, 47
(1
), pp. 55
–60
.9.
Zhao
, M. X.
, and Balachandran
, B.
, 2001
, “Dynamics and Stability of Milling Process
,” Int. J. Solids Struct.
, 38
, pp. 2233
–2248
.10.
Smith
, S.
, and Tlusty
, J.
, 1992
, “Stabilizing Chatter by Automatic Spindle Speed Regulation
,” Annals of the CIRP
, 41
(1).11.
Winfough
, W. R.
, and Smith
, S.
, 1995
, “Automatic Selection of the Optimum Metal Removal Conditions for High-Speed Milling
,” Transactions of NAMRI
, XXIII
, pp. 163
–168
.12.
Jayaram
, S.
, Kapoor
, S. G.
, and DeVor
, R. E.
, 2000
, “Analytical Stability Analysis of Variable Spindle Speed Machining
,” J. Manufacturing Science and Engineering
, 122
(3
), pp. 391
–397
.13.
Renton
, D.
, and Elbestawi
, M. A.
, 2000
, “High Speed Servo Control of Multi-Axis Machine Tools
,” Int. J. Mach. Tools Manuf.
, 40
, pp. 539
–559
.14.
Hogan
, B.
, 1999
, “No Speed Limits
,” Manuf. Eng.
, 3
, pp. 66
–78
.15.
Yan
, X.
, Shirase
, K.
, Hirao
, M.
, and Yasui
, T.
, 2000
, “Evaluation and Improvement of Productivity in High-Speed NC Machining
,” J. Manuf. Sci. Eng.
, 122
(3
), pp. 556
–561
.16.
Tlusty
, J.
, Smith
, S.
, and Zamudio
, C.
, 1990
, “New NC Routines for Quality in Milling
,” Annals of the CIRP
, 39
(1
), pp. 517
–521
.17.
Smith
, S.
, Cheng
, E.
, and Zamudia
, C.
, 1991
, “Computer-Aided Generation of Optimum Chatter-Free Pockets
,” J. Mater. Process. Technol.
, 28
, pp. 275
–283
.18.
Stori
, J. A.
, King
, C.
, and Wright
, P. K.
, 1999
, “Integration of Process Simulation in Machining Parameter Optimization
,” J. Manuf. Sci. Eng.
, 121
(1
), pp. 134
–143
.19.
Stori
, J. A.
, and Wright
, P. K.
, 2001
, “Parameter Space Decomposition for Selection of the Axial and Radial Depth of Cut in Endmilling
,” J. Manuf. Sci. Eng.
, 123
(4
), pp. 654
–664
.20.
Stori
, J. A.
, and Wright
, P. K.
, 2000
, “Constant Engagement Tool-Path Generation for Convex Geometries
,” J. Manuf. Syst.
, 19
(3
), pp. 172
–184
.21.
Kramer
, T. R.
, 1992
, “Pocket Milling With Tool Engagement Detection
,” J. Manuf. Syst.
, 11
(2
), pp. 114
–123
.22.
Tobias, S. A., 1965, Machine-Tool Vibration, Blackie and Sons Ltd, Glasgow, Scotland.
23.
Merrit
, H.
, 1965
, “Theory of Self-Excited Machine Tool Chatter
,” J. Eng. Ind.
, 87
(4
), pp. 447
–454
.24.
Koenisberger, F., and Tlustly, J., “Machine Tool Structures—Vol I: Stability Against Chatter,” Pergamon Press.
25.
Minis
, I.
, Yanushevsky
, T.
, Tembo
, R.
, and Hocken
, R.
, 1990
, “Analysis of Linear and Nonlinear Chatter in Milling
,” Annals of the CIRP
, 39
(1
), pp. 459
–462
.26.
Zeck
, M.
, Altinas
, Y.
, and Beer
, C.
, 1993
, “CAD Assisted Chatter-Free NC Tool Path Generation in Milling
,” Int. J. Mach. Tools Manuf.
, 34
(6
), pp. 879
–891
.27.
Abrari
, F.
, Elbestawi
, M. A.
, and Spence
, A. D.
, “On the Dynamics of Ball End Milling: Modeling of Cutting Force and Stability Analysis
,” Int. J. Mach. Tools Manuf.
, 38
(6
), pp. 215
–237
.28.
Farouki
, R. T.
, Tsai
, Yi-Feng
, and Wilson
, C. S.
, 2000
, “Physical Constraints on Feedrates and Feed Accelerations Along Curved Tool Paths
,” Comput. Aided Geom. Des.
, 17
, pp. 337
–359
.29.
Stori
, J. A.
, and Ferreria
, P. M.
, 2002
, “Design of a High-Speed Parallel Kinematics X-Y Table and Optimal Velocity Scheduling for High-Speed Machining
,” Transactions of NAMRI
, XXX
, 447
–454
.30.
Wang
, K. K.
, 1988
, “Solid Modeling for Optimizing Metal Removal of Three-Dimensional NC End Milling
,” J. Manuf. Syst.
, 7
(1
), pp. 57
–65
.31.
Yang
, M. Y.
, and Sim
, C. G.
, 1993
, “Reduction of Machining Errors by Adjustment of the Ball-End Milling Process
,” Int. J. Prod. Res.
, 31
(3
), pp. 665
–689
.32.
Fussell
, B. K.
, Jerard
, R. B.
, and Hemmett
, J. G.
, 2001
, “Robust Feedrate Selection for 3-Axis NC Machining Using Discrete Models
,” J. Manuf. Sci. Eng.
, 123
(2
), pp. 214
–224
.33.
Tsai
, M. D.
, Takata
, S.
, Inui
, M.
, Kimura
, F.
, and Sata
, T.
, 1991
, “Operation Planning Based on Cutting Process Models
,” Annals of the CIRP
, 40
(1
), pp. 95
–98
.34.
Iwabe
, H.
, Fujii
, Y.
, Saito
, K.
, and Kisinami
, T.
, 1989
, “Study of Corner Cut by End Mill—Analysis of Cutting Mechanism and New Cutting Method ant Inside Corner
,” J. of JSPE
, 55
(5
), pp. 841
–846
(in Japanese).35.
Bieterman, M. B., and Sandstrom, D. R., 2002, “A Curvilinear Tool-Path Method for Pocket Machining,” ASME IMECE2002-MED-33611.
36.
Li
, D.
, Yang
, J.-B.
, and Biswal
, M. P.
, 1999
, “Quantitative Parametric Connections Between Methods for Generating Noninferior Solutions in Multiobjective Optimization
,” Eur. J. Oper. Res.
, 117
, pp. 84
–89
.37.
Chou
, J.-J.
, and Yang
, D. C. H.
, 1991
, “Command Generation for Three-Axis CNC Machining
,” J. Eng. Ind.
, 113
, pp. 305
–310
.38.
Stoker, J. J., 1989, Differential Geometry, Wiley-Interscience, New York.
39.
Shirman
, L. A.
, and Sequin
, C. H.
, 1991
, “Procedural Interpolation With Geometrically Continuous Cubic Splines
,” Computer-Aided Design
, 24
(5
), pp. 267
–277
.Copyright © 2005
by ASME
You do not currently have access to this content.
