Journal
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
Volume 95, Issue 5-8, Pages 1607-1615Publisher
SPRINGER LONDON LTD
DOI: 10.1007/s00170-017-1243-8
Keywords
Optimal cutting direction; Tool paths generation; Sculptured surface; Contour error; Following error; Dynamic mismatch
Funding
- National Natural Science Funds of China [51775421]
- Major Project of High-end CNC Machine Tool and Basic Manufacturing Equipment of China [2015ZX04001002]
- China Postdoctoral Science Foundation [2015M570824]
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Tool path generation is one of the key challenges in multi-axis sculptured surface machining. Besides geometry accuracy, machining processes have been considered in tool path generation in order to improve machining quality and efficiency as far as possible. However, so far, the machine tool accuracies have not been yet fully taken into account during tool path generation. Contour accuracy is one of the most important precision indexes to guarantee the machining quality of sculptured surfaces. One of the major reasons causing contour error is the dynamic mismatch between feed axes of machine tools. In this study, the mathematic relationship between the cutting direction, dynamic mismatch of feed axes and contour error is theoretically established. The mathematic relationship can be used to calculate the optimal cutting directions which minimize the contour error caused by dynamic mismatch between feed axes during machining a sculptured surface by a three-axis machine tool. A machining experiment is carried out to verify the mathematic relationship. In the experiment, the tool paths are generated along the optimal cutting direction and other cutting directions for comparison. The results show that the contour error under the case of the optimal cutting direction is much smaller than that under the other cases.
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