Tool path planning of ball-end milling of free-form surfaces as a search algorithm

Authors

DOI:

https://doi.org/10.14513/actatechjaur.00736

Keywords:

Working diameter, Ball-end tool, Free-form surface, Surface roughness, Three-axis milling

Abstract

This paper introduces an innovative approach for generating three-axis CNC tool paths for machining free-form surfaces. The method is designed to minimize variations in the effective tool diameter, addressing a common challenge encountered when using ball-end tools for machining free-form surfaces. These surfaces exhibit varying inclinations, leading to fluctuations in the tool’s working diameter from one point to another, resulting in inconsistent cutting speeds and milling parameters despite a constant spindle speed. Consequently, the machined surface tends to lack uniformity. In contrast to conventional tool path planning techniques, the proposed method calculates the working diameter at each adjacent point and guides the tool’s movement towards the point where the smallest change in working diameter is anticipated. This approach reduces fluctuations in cutting speed and promotes the generation of a more homogeneous surface.

Downloads

Download data is not yet available.

References

Q. Zou, J. Zhang, B. Deng, and J. Zhao, Iso-level tool path planning for free-form surfaces. Computer-Aided Design 53 (2014) pp.117–125. https://doi.org//10.1016/j.cad.2014.04.006

L. C. Magalhães and J. C. E. Ferreira, Assessment of tool path strategies for milling complex surfaces in hardened H13 steel. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 233 (3) (2019) pp. 834–849. https://doi.org// 10.1177/0954405418755824

X. Niu, T. Wang, B. Shen, T. Zhao, and Q. Huang, Study on Tool Path Optimization in Multi-axis NC Machining. MATEC Web of Conferences 34 (2015) 02012. https://doi.org//10.1051/matecconf/20153402012

Y. Sun, J. Jia, J. Xu, M. Chen, and J. Niu, Path, feedrate and trajectory planning for free-form surface machining: A state-of-the-art review. Chinese Journal of Aeronautics 35 (8) (2022) pp. 12–29. https://doi.org//10.1016/j.cja.2021.06.011

J. Varga, T. Tóth, Ľ. Kaščák, and E. Spišák, The Effect of the Machining Strategy on the Surface Accuracy When Milling with a Ball End Cutting Tool of the Aluminum Alloy AlCu4Mg. Applied Sciences 12 (20) (2022) 10638. https://doi.org//10.3390/app122010638

D.-D. Vu, F. Monies, and W. Rubio, A new optimization tool path planning for 3-axis end milling of free-form surfaces based on efficient machining intervals. AIP Conference Proceedings (2018) 070011. https://doi.org//10.1063/1.5034907

G. Huo et al., CNC Tool Path Generation for Freeform Surface Machining Based on Preferred Feed Direction Field. International Journal of Precision Engineering and Manufacturing 20 (5) (2019) pp. 777–790. https://doi.org//10.1007/s12541-019-00084-2

R. A. Mali, R. Aiswaresh, and T. V. K. Gupta, The influence of tool-path strategies and cutting parameters on cutting forces, tool wear and surface quality in finish milling of Aluminium 7075 curved surface. The International Journal of Advanced Manufacturing Technology 108 (1-2) (2020) pp. 589–601. https://doi.org//10.1007/s00170-020-05414-7

A. Kukreja and S. S. Pande, Optimal toolpath planning strategy prediction using machine learning technique. Engineering Applications of Artificial Intelligence 123 (2023) 106464. https://doi.org//10.1016/j.engappai.2023.106464

U. Župerl, K. Stepien, G. Munđar, and M. Kovačič, A Cloud-Based System for the Optical Monitoring of Tool Conditions during Milling through the Detection of Chip Surface Size and Identification of Cutting Force Trends. Processes 10 (4) (2022) p. 671. https://doi.org//10.3390/pr10040671

J. Zhang, R. Mo, N. Wan, and C. Xia, Tool path planning for five-axis flank milling of free-form surfaces. The International Journal of Advanced Manufacturing Technology 108 (1-2) (2020) pp. 73–90. https://doi.org//10.1007/s00170-020-05283-0

A. Kukreja and S. S. Pande, An Efficient Iso-Scallop Toolpath Planning Strategy Using Voxel-Based Computer Aided Design Model, Journal of Computing and Information Science in Engineering 23 (3) (2023) 031009. https://doi.org//10.1115/1.4055372

W. Liu, S.-M. Zhu, T. Huang, and C. Zhou, An efficient iso-scallop tool path generation method for three-axis scattered point cloud machining. The International Journal of Advanced Manufacturing Technology 107 (7-8) (2020) pp. 3471–3483. https://doi.org//10.1007/s00170-020-05188-y

W. Liu, L. Zhou, and L. An, Constant scallop-height tool path generation for three-axis discrete data points machining. The International Journal of Advanced Manufacturing Technology 63 (1-4) (2012) pp. 137–146. https://doi.org//10.1007/s00170-011-3892-3

A. Mgherony and B. Mikó, Controlling the Spindle Speed when Milling Free-Form Surfaces using Ball-End Milling Cutter, Acta Polytechnica Hungarica 20 (6) (2023) pp. 135–149. https://doi.org//10.12700/APH.20.6.2023.6.8

B. Mikó and P. Zentay, A geometric approach of working tool diameter in 3-axis ball-end milling. The International Journal of Advanced Manufacturing Technology 104 (1-4) (2019) pp. 1497–1507. https://doi.org//10.1007/s00170-019-03968-9

Downloads

Published

2024-03-14

How to Cite

Mgherony, A., & Mikó, B. (2024). Tool path planning of ball-end milling of free-form surfaces as a search algorithm. Acta Technica Jaurinensis, 17(2), 75–83. https://doi.org/10.14513/actatechjaur.00736

Issue

Section

Research articles