Method of Planning Tool Postures for Deep Groove Machining of Complex Shapes – Development of an Automatic Planning Method that Considers the Motions of the Rotational Axis when the Tool Reverses Direction in Grooved Shapes –

Kohei Ichikawa; Jun’ichi Kaneko; Masanobu Hasegawa; Takayuki Iwasaki; Kenichiro Horio

doi:10.20965/ijat.2017.p0226

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IJAT Vol.11 No.2 pp. 226-234

doi: 10.20965/ijat.2017.p0226

(2017)

Paper:

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Method of Planning Tool Postures for Deep Groove Machining of Complex Shapes – Development of an Automatic Planning Method that Considers the Motions of the Rotational Axis when the Tool Reverses Direction in Grooved Shapes –

Kohei Ichikawa^,†, Jun’ichi Kaneko^, Masanobu Hasegawa^, Takayuki Iwasaki^, and Kenichiro Horio^*

^*Saitama University
255 SimoOkubo, Sakura-ku, Saitama City, Saitama 338-8570, Japan

^†Corresponding author

^**IHI Corporation, Yokohama, Japan

Received:

August 24, 2016

Accepted:

October 28, 2016

Published:

March 1, 2017

Keywords:

5-axis machining, deep groove, CAM, tool posture planning

Abstract

Simultaneous 5-axis control machining is used to machine components in complex, deep grooved shapes. In order to maintain actual feed rates in this kind of machining, it is vitally important to secure continuity in the movement of the rotational axis. When the tool reverses its direction of travel, however, its axis of rotation is liable to make sudden movements. In this study, therefore, we first derive candidate tool postures that can meet the conditions for relative postures to machined surfaces while avoiding tool interferences. We then develop a method for automatically planning continuous changes in the command values of the rotating axial angles in the machine coordinate space.

Cite this article as:

K. Ichikawa, J. Kaneko, M. Hasegawa, T. Iwasaki, and K. Horio, “Method of Planning Tool Postures for Deep Groove Machining of Complex Shapes – Development of an Automatic Planning Method that Considers the Motions of the Rotational Axis when the Tool Reverses Direction in Grooved Shapes –,” Int. J. Automation Technol., Vol.11 No.2, pp. 226-234, 2017.

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References

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[12] J. Kaneko, Y. Yamauchi, and K. Horio, “Fast Estimation Method of Machinable Area of Workpiece Surface for 3+2-Axis Control Machining Using Graphics Device,” Int. J. of Automation Technology, Vol.8, No.3, 2014.
[13] J. Kaneko and K. Horio, “Fast Determination Method of Tool Posture for 5-axis Control Machining Using Graphics Hardware,” J. of the Japan Society for Precision Engineering, Vol.72, No.8, 2006 (in Japanese).
[14] K. Saito, H. Aoyama, and N. Sano, “Accurate Estimation of Cutting Time Based on Control Principle of Machine Tool,” Int. J. of Automation Technology, Vol.10, No.3, 2016.
[15] M. Nagasaka and Y. Takeuchi, “Generalized Post-Processor for 5-Axis Control Machining Based on Form Shape Function,” J. of the Japan Society for Precision Engineerin, Vol.62, No.11, 1996.
[16] D. Kono, S. Weikert, A. Matsubara, and K. Yamazaki, “Estimation of Dynamic Mechanical Error for Evaluation of Machine Tool Structures,” Int. J. of Automation Technology, Vol.6, No.2, 2012.
[17] R. Sato and M. Tsutsumi, “High Performance Motion Control of Rotary Table for 5-Axis Machining Center,” Int. J. of Automation Technology, Vol.1, No.2, 2007.
[18] J. Kaneko and K. Horio, “Workpiece Fixture Planning Method for Continuous Multi-Axis Machining with Consideration of Motion on Translational Axis,” Int. J. of Automation Technology, Vol.6, No.6, 2012.
[19] T. Hikichi, K. Nakamoto, T Ishida, and Y. Takeuchi, “Development of CAM System for 5-axis Control Machining by Considering Tool Attitude and Attitude Variation,” J. of the Japan Society for Precision Engineering, Vol.77, No.8, 2011 (in Japanese).
[20] J. Kaneko and K. Horio, “Tool Posture Planning Method for Continuous 5-Axis Control Machining on Machine Tool Coordinate System to Optimize Motion of Translational Axes,” Int. J. of Automation Technology, Vol.5, No.5, 2011.

This article is published under a Creative Commons Attribution-NoDerivatives 4.0 Internationa License.

[1] [1] S. Igari, F. Tanaka, and M. Onosato, “Computer-Aided Operation Planning for an Actual Machine Tool Based on Updatable Machining Database and Database-Oriented Planning Algorithm,” Int. J. of Automation Technology, Vol.6, No.6, 2012.

[2] [2] T. Oba, K. Nakamoto, T. Ishida, and Y. Takeuchi, “Development of CAPP/CAM System for 5-axis Control Machining,” J. of the Japan Society for Precision Engineering, Vol.76, No.1, 2010 (in Japanese).

[3] [3] X. X. Chen, J. Zhao, Y. Dong, S. Han, A. Li, and D. Wand, “Effects of inclination angles on geometrical features of machined surface in five-axis milling,” Int. J. Adv Manuf Technol, Vol.65, pp. 721-1733, 2013.

[4] [4] R. Sato, Y. Yokobori, and M. Tsutsumi, “Dynamic Synchronous Accuracy of Translational Axes and Rotational Axes in 5-axis Machining Center,” J. of the Japan Society for Precision Engineering, Vol.72, No.1, 2006 (in Japanese).

[5] [5] K. Morishige and M. Kaneko, “Tool Path Generation for Five-axis Controlled Machining with Consideration of motion of two Rotation Axes,” Int. J. of Automation Technology, Vol.5, No.3, 2011.

[6] [6] Y. Fujino and K. Morishige, “Tool Path Generation for Five-axis Controlled Machining with Consideration of Movable Range of Machine Tool and Tool Attitude Change,” J. of the Japan Society for Precision Engineering, Vol.74, No.12, 2008 (in Japanese).

[7] [7] H. Wakayama and K. Morishige, “Optimum Tool Path Generation for 5-Axis Control Machining Considering Tool Attitude Change,” J. of the Japan Society for Precision Engineering, Vol.71, No.5, 2005 (in Japanese).

[8] [8] E. Ozturk, L. T. Tunc, and E. Budak, “Investigation of lead and tilt angle effects in 5-axis ball-end milling processes,” Int. J. of Machine Tools and Manufacture, Vol.49, Issue 14, 2009.

[9] [9] T. Kanda and K. Morishige, “Tool Path Generation for Five-Axis Controlled Machining with Consideration of Tool and Structure Interference,” J. of the Japan Society for Precision Engineering, Vol.81, No.10, 2015 (in Japanese).

[10] [10] T. Moller, “Fast minimum storage ray-triangle intersection,” J. Of Graphics Tools, Vol.2, No.1, 1997.

[11] [11] J. Kaneko and K. Horio, “Fast Cutter Workpiece Engagement Estimation Method for Prediction of Instantaneous Cutting Force in Continuous Multi-Axis Controlled Machining,” Int. J. of Automation Technology, Vol.7, No.4, 2013.

[12] [12] J. Kaneko, Y. Yamauchi, and K. Horio, “Fast Estimation Method of Machinable Area of Workpiece Surface for 3+2-Axis Control Machining Using Graphics Device,” Int. J. of Automation Technology, Vol.8, No.3, 2014.

[13] [13] J. Kaneko and K. Horio, “Fast Determination Method of Tool Posture for 5-axis Control Machining Using Graphics Hardware,” J. of the Japan Society for Precision Engineering, Vol.72, No.8, 2006 (in Japanese).

[14] [14] K. Saito, H. Aoyama, and N. Sano, “Accurate Estimation of Cutting Time Based on Control Principle of Machine Tool,” Int. J. of Automation Technology, Vol.10, No.3, 2016.

[15] [15] M. Nagasaka and Y. Takeuchi, “Generalized Post-Processor for 5-Axis Control Machining Based on Form Shape Function,” J. of the Japan Society for Precision Engineerin, Vol.62, No.11, 1996.

[16] [16] D. Kono, S. Weikert, A. Matsubara, and K. Yamazaki, “Estimation of Dynamic Mechanical Error for Evaluation of Machine Tool Structures,” Int. J. of Automation Technology, Vol.6, No.2, 2012.

[17] [17] R. Sato and M. Tsutsumi, “High Performance Motion Control of Rotary Table for 5-Axis Machining Center,” Int. J. of Automation Technology, Vol.1, No.2, 2007.

[18] [18] J. Kaneko and K. Horio, “Workpiece Fixture Planning Method for Continuous Multi-Axis Machining with Consideration of Motion on Translational Axis,” Int. J. of Automation Technology, Vol.6, No.6, 2012.

[19] [19] T. Hikichi, K. Nakamoto, T Ishida, and Y. Takeuchi, “Development of CAM System for 5-axis Control Machining by Considering Tool Attitude and Attitude Variation,” J. of the Japan Society for Precision Engineering, Vol.77, No.8, 2011 (in Japanese).

[20] [20] J. Kaneko and K. Horio, “Tool Posture Planning Method for Continuous 5-Axis Control Machining on Machine Tool Coordinate System to Optimize Motion of Translational Axes,” Int. J. of Automation Technology, Vol.5, No.5, 2011.

Method of Planning Tool Postures for Deep Groove Machining of Complex Shapes – Development of an Automatic Planning Method that Considers the Motions of the Rotational Axis when the Tool Reverses Direction in Grooved Shapes –

Kohei Ichikawa*,†, Jun’ichi Kaneko*, Masanobu Hasegawa**, Takayuki Iwasaki**, and Kenichiro Horio*

Kohei Ichikawa^,†, Jun’ichi Kaneko^, Masanobu Hasegawa^, Takayuki Iwasaki^, and Kenichiro Horio^*