A new approach to find gouge free tool positions for a toroidal cutter for Bezier surfaces in Five axis machining

We implement and test a multi-point machining tool positioning technique that positions the tool using only a variation on gouge checking. The result is a method that is roughly twice as fast as an earlier method that performed a numerical search to find a tool position with multiple points of contact with the design surface. A GPU implementation provides an additional factor of ten speedup. Verification of the method was done via simulation and machining and measuring physical parts.

Five-axis milling of sculptured surfaces of the turbine blade

Purpose The purpose of this paper is to determine the influence of a toroidal cutter axis orientation and a variable radius of curvature of the machined contour of sculptured surface on the five-axes milling process. Simulation and experimental research performed in this work are aimed to determine the relationship between the parameters of five-axes milling process and the shape and dimensional accuracy of curved outline of Inconel 718 alloy workpiece. Design/methodology/approach A subject of research are sculptured surfaces of the turbine blade. Simulation research was performed using the method of direct mapping tools in the CAD environment. The machining research was carried out with the use of multi-axis machining center DMU 100 monoBLOCK DMG, equipped with rotating dynamometer to measure the components of the cutting force. To control the shape and dimensional accuracy, the coordinate measuring machine ZEISS ACCURA II was used. Findings In this paper, the effect of the toroidal cutter axis orientation and the variable radius of curvature of the machined contour on the parameters of five-axes milling process and the accuracy of the sculptured surfaces was determined. Practical implications Five-axes milling with the use of a toroidal cutter is found in the aviation industry, where sculptured surfaces of the turbine blades are machined. The results of the research allow more precise planning of five-axes milling and increase of the turbine blades accuracy. Originality/value This paper significantly complements the current state of knowledge in the field of five-axes milling of turbine blades in terms of their accuracy.

Cutting layer and cutting forces in a 5-axis milling of sculptured surfaces using the toroidal cutter

The purpose of this article was to evaluate the significance of the influence of five- axis orientation parameters of a toroidal cutter axis and the geometrical parameters of the machined sculptured surface on the intersection of the cut layer in a 5-axis machining. An impact assessment was performed by simulating concave-convex and convex-concave surfaces using a discrete method of direct transformation in a CAD environment. It was shown that only the radius of curvature of the surface in the feed direction and the angle of the tool axis affected the change in the intersection of the cutting layer. Subsequently, experimental tests were conducted that aimed at determining the mathematical models of the influence of these important parameters on the components of the cutting force. The object of the experimental studies was a convex and concave surface of a turbine blade of Inconel 718 alloy. The R300-016B20L-08L Sandvik Coromant toroid cutter was used for the tests. Based on the results of the study it was found that the lead angle in the machining of the convex surface and concave turbine blade should be continuously varied with the change of radius of curvature in the direction of the machined surface profile

Effect of kinematic and geometric parameters on the cut layer in a 5-axis machining of the sculptured surfaces

Results of simulation studies made using the direct CAD method are presented. The significance of the influence of the toroidal cutter axis orientation parameters and curvature radius of the sculptured surface on the cut layer in a 5-axis milling of the convex-concave and concave-convex surfaces, was assessed.

Method of controlling the lead angle of the toroidal cutter axis in 5-axis machining of the turbine blade

Presented is the own concept control method an lead angle axis of the toroidal cutter, depending on the radius of curvature of the machined sculptured surface profile. The method verified on the example machining of the turbine blade. In order to compare the effects of this method, to the classical method (without adaptation lead angle), tests were performed for both these methods.

Analytical Boundary Method for Obtaining Feed Scallop of Toroidal Cutter in Multi-Axis Milling

This paper presents a new method to calculate the feed scallop height for a toroidal cutter during a free-form surface machining in multi-axis milling. The proposed method is an extended analytical boundary method to define the cut geometry during a free-form surface milling. The algorithm was developed by taken into account the existence of inclination angle. The proposed method was successfully implemented to calculate the scallop for two model parts with different surface profiles. The accuracy was verified by comparing the scallop height calculated using the proposed method with those measured using Siemens-NX. The results proved that the proposed method was accurate