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1998 | Buch

Introduction to sculptured surface machining Kapitel lesen Erstes Kapitel lesen

Sculptured Surface Machining

Theory and applications

verfasst von: Byoung K. Choi, Robert B. Jerard

Verlag: Springer US

Enthalten in: Professional Book Archive

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Über dieses Buch

Sculptured Surface Machining (SSM) plays a vital role in the process of bringing new products to the market place. A great variety of products, from automotive body-panels to mobile phones, rely on this technology for the machining of their dies and moulds. This book documents the latest research progress and key issues affecting SSM software development. With a particular focus on the CAD/CAM environment, this book provides a rich source of reference, and covers such topics as fundamental mathematical tools, SSM-process models, process planning models and key tool-path generator (TPG), in addition to discussing more advanced theory and technology such as the new `C-space'- based TPG methods and `cloud-of-points' data machining.
Sculptured Surface Machining: Is the first book to discuss all aspects of SSM, from SSM-process models to SSM- software design methodologies Presents a feature-based CAPP (computer-automated process planning) methodology for sculptured surface machining Includes practical applications for NC machining technologies.
This book is essential reading for manufacturing engineers producing products with sculptured surfaces, software engineers working with CAD/CAM software, and researchers in the fields of mechanical, production and industrial engineering, and computer science.

Inhaltsverzeichnis

Frontmatter

Fundamentals of Sculptured Surface Machining

Frontmatter
1. Introduction to sculptured surface machining
Abstract
Many products are designed with aesthetic sculptured surfaces to enhance their aesthetic appeal, an important factor in customer satisfaction, especially for automotive and consumer-electronics products. In other cases, products have sculptured shapes to meet functional requirements. Examples of functional sculptured surfaces are:
  • aerodynamic: airfoil (jet engine), impeller (compressor), marine propeller, etc.;
  • optical: lamp reflector (automobile), shadow mask (TV-monitor), radar-dish, etc.;
  • medical: parts for anatomical reproduction;
  • structural: structural frames (aircraft), sporting goods, etc.;
  • manufacturing surface: parting surface (moulding die), die face (stamping die), etc.
Byoung K. Choi, Robert B. Jerard
2. Mathematical background
Abstract
Presented in this chapter is basic mathematical background for sculptured surface machining. Topics to be discussed are: the basics and application of vector algebra; coordinate transformations; basics of curve and surface geometry; curve and surface differential geometry. Throughout the chapter, lower-case bold is used for vectors or points in a Cartesian coordinate system and UPPER-CASE BOLD for matrices.
Byoung K. Choi, Robert B. Jerard
3. Sculptured surface machining processes
Abstract
Improved methods for sculptured surface machining (SSM) must be based on (1) a formal framework for describing the SSM-processes and (2) an understanding of industrial practices. Therefore, this chapter presents a unified SSM-process model consisting of a set of unit machining operations (UMOs), machining-stage formation schemes, and UMOs for 5-axis machining. To help the reader appreciate current industrial practices, three examples of SSM-processes are presented: stamping-die machining, injection moulding-die machining and airfoil machining. In particular, the ‘UMO-description format’ proposed in this chapter could help enhance communication between industrial developers and academic researchers.
Byoung K. Choi, Robert B. Jerard
4. Process planning for sculptured surface machining
Abstract
The purpose of this chapter is to present the SSM-process planning problem in a structured manner. Topics to be discussed in this chapter include: (1) the basic structure of process planning models, (2) concepts of freeform-features and machining-features, and (3) an approach to feature-based process planning. The subject of process planning is treated such that the material presented in this chapter can be used (1) in developing computer-automated process planning (CAPP) systems as well as (2) as a practical guide for planning SSM-operations during CAM programming.
Byoung K. Choi, Robert B. Jerard
5. Fundamentals of tool-path generation and validation
Abstract
The purpose of this chapter is to provide an overview of tool-path generation and validation for sculptured surface machining (SSM). Major topics to be discussed in this chapter include: (1) issues in planning tool-path topology and selecting milling-strategy options, (2) tool-path resolution planning, (3) CL-data computation, (4) cutter-interference handling, (5) basics of cutting simulation and NC verification, and (6) issues in cutting condition determination.
Byoung K. Choi, Robert B. Jerard

Tool-Path Generation Methods for Sculptured Surface Machining

Frontmatter
6. Introduction to tool-path generation methods
Abstract
As an introduction to Part Two, this chapter provides a comprehensive review of the ‘conventional’ tool-path generation methods and proposes a new tool-path generation method called the ‘C-space method’. The conventional methods to be covered in this chapter are isoparametric methods, Cartesian methods and APT-type methods. In this book, the C-space method will be exclusively used in generating 3-axis NC tool-paths.
Byoung K. Choi, Robert B. Jerard
7. Tool-path generation for roughing
Abstract
Presented in this chapter are C-space based tool-path generation methods for roughing, with a special emphasis on pocket machining. Topics to be discussed are (1) characteristics of roughing operations, (2) CL-surface construction for roughing, (3) tool-path generation for pocket-machining, (4) 2D offsetting for CPO tool-path generation, (5) handling of uncuts in pocketing, (6) special issues in pocket-machining and (7) C-space approach to collision detection.
Byoung K. Choi, Robert B. Jerard
8. Tool-path generation for finishing
Abstract
The purpose of a finishing operation in an SSM-process is to generate a smooth surface ‘region’, and as a result, finish-machining is often called regional milling. Thus, we will use the term ‘regional milling’ to refer to finish-machining (as well as semi-finishing). Presented in this chapter are C-space based methods for generating regional milling NC tool-paths. Topics to be discussed are (1) issues in generating NC tool-paths for regional milling, (2) path-resolution planning and tool-path generation, (3) tool-path linking and (4) cutting-load smoothing for milling efficiency.
Byoung K. Choi, Robert B. Jerard
9. Tool-path generation for clean-up machining
Abstract
The purpose of clean-up machining is to remove uncut volumes, which are left at concave regions after finish-machining, by employing small-size cutters. The clean-up UMOs to be discussed in this chapter are the fillet-cut [BEM] and pencil-cut [BEM], where BEM denotes ball-endmill cutter. Presented in this chapter are details of the C-space approach to generating clean-up tool-paths. Topics to be discussed include: (1) characteristics of clean-up tool-path generation, (2) Z-map based pencil-curve tracing methods, (3) point-data fairing methods, (4) a method for generating pencil-cut tool-paths and (5) a method for generating fillet-cut tool-paths.
Byoung K. Choi, Robert B. Jerard
10. Cloud-of-points data machining for reverse engineering
Abstract
The purpose of reverse engineering is to obtain a shape model of the digitized object, in the form of a geometric model, machined object, RP part etc. Regardless of the final form of the shape model, reverse engi­neering consists of three major phases: digitizing, surface construction and shape-model creation. Presented in this chapter is a step-by-step procedure for generating NC tool-paths from optically digitized data, better known as cloud-of-points data, generated by laser-scanning machines of a specific type.
Byoung K. Choi, Robert B. Jerard
11. Five axis machining
Abstract
In theory, five axis machining of sculptured surfaces offers many advantages over three axis machining, including faster material removal rates, improved surface finish and the elimination of hand finishing. Vickers and Quan (1989) report that efficiency gains of 10–20 fold can be achieved by using five axis machining instead of three axis machining. In practice, five axis machining suffers from a number of drawbacks, mostly related to gouge avoidance. This chapter focuses on methods for generation of gouge-free, non-isoparametric 5-axis tool-paths across composite surface patches using a flat-endmill. Elements of the method include: (1) tessellation of the parametric surfaces into triangles, (2) algorithms for placement of a cylindrically shaped cutting tool onto the triangulated surface, and (3) interference detection and tool position correction.
Byoung K. Choi, Robert B. Jerard

Controlling Accuracy and Quality in Sculptured Surface Machining

Frontmatter
12. Geometric cutting simulation and verification
Abstract
In order to achieve the productivity gains described in section 1.2 of this book, it is required that machine tools operate with a reduced level of operator supervision. Ideally, the NC machine would be running in an unmanned mode. The use of simulation and verification is essential if programs are to be run with confidence in unmanned operation. While simple NC programs for prismatic parts can be tested ‘at the mill’, and then run repetitively on subsequent parts, sculptured surface parts are often ‘one of a kind’. This chapter presents various methods for performing the geometric simulation and verification of SSM-processes. The next chapter will present methods for simulating the physical cutting process, an important component for selecting cutting conditions that are both safe and efficient.
Byoung K. Choi, Robert B. Jerard
13. Cutting force modelling and physical cutting simulation
Abstract
There is a direct relationship between the cutting conditions and the economics of the SSM-process. The goal is to cut the part as quickly as possible while maintaining safe cutting conditions and high part quality. The simulation of the physical process must be capable of estimating the cutting forces. The cutting force information may be used to verify that: (1) the cutter teeth will not break, (2) the spindle motor power is sufficient, (3) the bending stresses in the shank will not cause the tool to break and (4) the tool deflection will not cause the part to deviate from the required tolerance.
Byoung K. Choi, Robert B. Jerard

Systems Integration for Sculptured Surface Machining

Frontmatter
14. A unified CAM-system architecture
Abstract
The tool-path generation methods (TPG) in the previous chapters may be regarded as ‘component technologies’, while a CAM-system (or SSMsoftware) is a ‘product’ to be used in an SSM-system. A component technology would serve its purpose only when it is realized into a useful product. Discussed in the final part of this book are issues in developing a product (SSM-software) which is compatible with the requirements of the user (SSM-system). As an introduction to Part Four, this chapter presents a unified CAM-system architecture proposed by Choi et al. (1994). A new framework for developing an integrated SSM-software will be presented in the next chapter, followed by a practical CAPPsystem architecture proposed in Chapter 16.
Byoung K. Choi, Robert B. Jerard
15. Development of Integrated SSM-software
Abstract
In Chapter 1, we have identified 12 functional requirements that would contribute to the TQC (time-quality-cost) goal of a sculptured surface machining (SSM) system. Various component technologies, including a prototype CAM-system architecture, for developing an SSM-system have been introduced in the previous chapters. Proposed in this chapter is a ‘formal’ methodology for designing an integrated SSM-software system specialized in die-cavity machining which is capable of meeting the TQC-goal. The proposed methodology is somewhat based on the concept of axiomatic design (Suh, 1990). An SSM-system consists of SSM­software (or CAM-system), CAM-operators, NC machines, NC-opera­tors, tooling and tool-management systems etc.
Byoung K. Choi, Robert B. Jerard
16. CAPP for sculptured surface machining
Abstract
A truly integrated SSM-system may not be fully realized without CAPP (computer automated process planning). CAPP for rotational-part and prismatic-part machining has been an active research topic and a very large number of CAPP systems have reportedly been developed (Pratt, 1984; Kanumury and Chang, 1991; Alting and Zhang, 1989), but very little is published about CAPP for sculptured surface machining (Choi et al., 1996b).
Byoung K. Choi, Robert B. Jerard
Backmatter
Metadaten
Titel
Sculptured Surface Machining
verfasst von
Byoung K. Choi
Robert B. Jerard
Copyright-Jahr
1998
Verlag
Springer US
Electronic ISBN
978-1-4615-5283-3
Print ISBN
978-1-4613-7410-7
DOI
https://doi.org/10.1007/978-1-4615-5283-3