Cutter runout is a common and inevitable phenomenon impacting the geometry accuracy in the milling process. However, most of the works on tool path planning neglect the cutter runout effect. In this paper, a new approach is presented to integrate the cutter runout effect into envelope surface modeling and tool path optimization for five-axis flank milling with a conical cutter. Based on the geometry model of cutter runout which consists of cutter axis and cutter tilt, an analytic expression of cutter edge combined with four runout parameters is derived. Then the envelope surface formed by each cutter edge is constructed using the envelope theory of sphere congruence. Due to the cutter runout effect, the envelope surfaces formed by the cutter edges are different from each other, and the valid envelope surface is the combination of these envelope surfaces which contribute to the final machined surface. To measure the machining errors, the geometry deviations between the valid envelope surface and the design surface are calculated with the distance function. On the basis of the differential property of the distance function, tool path optimization considering cutter runout is modeled as a mixed-integer linear programming (MILP) problem, which can be solved by the branch-and-bound method. Finally, numerical examples are given to confirm the validity and efficiency of the proposed approach. The results show that the geometry errors induced by runout can be reduced significantly using the proposed method.
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August 2014
Research-Article
Envelope Surface Modeling and Tool Path Optimization for Five-Axis Flank Milling Considering Cutter Runout
Zhou-Long Li
,
Zhou-Long Li
State Key Laboratory of Mechanical System
and Vibration,
School of Mechanical Engineering,
e-mail: lzl@sjtu.edu.cn
and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University
,Shanghai 200240
, China
e-mail: lzl@sjtu.edu.cn
Search for other works by this author on:
Li-Min Zhu
Li-Min Zhu
1
State Key Laboratory of Mechanical System
and Vibration,
School of Mechanical Engineering,
e-mail: zhulm@sjtu.edu.cn
and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University
,Shanghai 200240
, China
e-mail: zhulm@sjtu.edu.cn
1Corresponding author.
Search for other works by this author on:
Zhou-Long Li
State Key Laboratory of Mechanical System
and Vibration,
School of Mechanical Engineering,
e-mail: lzl@sjtu.edu.cn
and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University
,Shanghai 200240
, China
e-mail: lzl@sjtu.edu.cn
Li-Min Zhu
State Key Laboratory of Mechanical System
and Vibration,
School of Mechanical Engineering,
e-mail: zhulm@sjtu.edu.cn
and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University
,Shanghai 200240
, China
e-mail: zhulm@sjtu.edu.cn
Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received January 20, 2014; final manuscript received April 5, 2014; published online June 5, 2014. Assoc. Editor: Xiaoping Qian.
1Corresponding author.
J. Manuf. Sci. Eng. Aug 2014, 136(4): 041021 (9 pages)
Published Online: June 5, 2014
Article history
Received:
January 20, 2014
Revision Received:
April 5, 2014
Citation
Li, Z., and Zhu, L. (June 5, 2014). "Envelope Surface Modeling and Tool Path Optimization for Five-Axis Flank Milling Considering Cutter Runout." ASME. J. Manuf. Sci. Eng. August 2014; 136(4): 041021. https://doi.org/10.1115/1.4027415
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