Determination of the feasible setup parameters of a workpiece to maximize the utilization of a five-axis milling machine

Abstract

The machining industry must maximize the machine tool utilization for its efficient and effective usage. Determining a feasible workpiece location is one of the significant tasks performed in an iterative way via machining simulations. The maximum utilization of five-axis machine tools depends upon the cutting system’s geometry, the configuration of the machine tool, and the workpiece’s location. In this research, a mathematical model has been developed to determine the workpiece’s feasible location in the five-axis machine tool for avoiding the number of iterations, which are usually performed to eliminate the global collision and axis limit errors. In this research, a generic arrangement of the five-axis machine tool has been selected. The mathematical model of post-processor has been developed by using kinematic modeling methods. The machine tool envelopes have been determined using the post-processor and axial limit. The tooltip reachable workspace is determined by incorporating the post-processor, optimal cutting system length, and machining envelope, thereby further developing an algorithm to determine the feasible workpiece setup parameters accurately. The algorithm’s application has been demonstrated using an example. Finally, the algorithm is validated for feasible workpiece setup parameters in a virtual environment. This research is highly applicable in the industry to eliminate the number of iterations performed for the suitable workpiece setup parameters.

Graphical abstract

Keywords

workpiece setup parameter / five-axis / space utilization / setup parameters / machine tool

References

[1] Altintas Y. Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Calibrations and CNC Design. Cambridge: Cambridge University Press, 2000

[2] Bohez E L J. Five axis milling machine tool kinematic chain design and analysis. International Journal of Machine Tools and Manufacture, 2002, 42(4): 505–520

[3] Stanislav S M, Weerachai A. Advance Numerical Method to Optimize Cutting Operations of Five-Axis Milling Machines. Berlin: Springer, 2007

[4] Lee Y S. Admissible tool orientation control of gouging avoidance for 5-axis complex surface machining. Computer-Aided Design, 1997, 29(7): 507–521

[5] Lo C. Efficient cutter-path planning for five axis surface machining with a flat-end cutter. Computer-Aided Design, 1999, 31(9): 557–566

[6] Gray P, Bedi S, Ismail F. Rolling ball method for 5-axis surface machining. Computer-Aided Design, 2003, 35(4): 347–357

[7] Gray P, Bedi S, Ismail F. Arc-intersection method for 5-axis tool positioning. Computer-Aided Design, 2005, 37(7): 663–674

[8] Choi B K, Park J W, Jun C S. Cutter location data optimization in 5-axis surface machining. Computer-Aided Design, 1993, 25(6): 377–386

[9] Jensen C G, Red W E, Pi J. Tool selection for five-axis curvature matched machining. Computer-Aided Design, 2002, 34(3): 251–266

[10] She C, Chang C. Design of a generic five-axis postprocessor based on generalized kinematics model of machine tool. International Journal of Machine Tools and Manufacture, 2007, 47(3–4): 537–545

[11] Jung Y H, Lee D W, Kim J S, NC postprocessor for 5-axis milling machine of table rotating/tilting type. Journal of Materials Processing Technology, 2002, 130–131: 641–646

[12] Chen L. Kinematics modelling and post processing method of five axis CNC machine. Proceedings of the 2009 First International Workshop on Education Technology and Computer Science, 2009, 1: 300–303

[13] Affouard A, Duc E, Lartigue C, Avoiding 5-axis singularities using tool path deformation. International Journal of Machine Tools and Manufacture, 2004, 44(4): 415–425

[14] Munlin M, Makhanov S S, Bohez E L J. Optimization of rotations of a five-axis milling machine near stationary points. Computer-Aided Design, 2004, 36(12): 1117–1128

[15] Anotaipaiboon W, Makhanov S S, Bohez E L J. Optimal setup for five-axis machining. International Journal of Machine Tools and Manufacture, 2006, 46(9): 964–977

[16] Chen Z C, Ahmed A. A precise approach for the determination of the setup parameters to utilize maximum workspace of five-axis CNC machine tools. International Journal of Advanced Manufacturing Technology, 2016, 85(9–12): 2297–2311

[17] Duong T, Rodriguez-Ayerbe P, Lavernhe S, Contour error pre-compensation for five-axis high speed machining: Offline gain adjustment approach. International Journal of Advanced Manufacturing Technology, 2019, 100(9–12): 3113–3125

[18] Sepahi-Boroujeni S, Mayers J R R, Khameneifar F. Repeatability of on-machine probing by a five-axis machine tool. International Journal of Advanced Manufacturing Technology, 2020, 152: 103544

[19] Lin Z, Fu J, Shen H, On the workpiece setup optimization for five-axis machining with RTCP function. International Journal of Advanced Manufacturing Technology, 2014, 74(1–4): 187–197

[20] Pessoles X, Landon Y, Segonds S, Optimisation of workpiece setup for continuous five-axis milling: Application to a five-axis BC type machining centre. International Journal of Advanced Manufacturing Technology, 2013, 65(1–4): 67–79

[21] Xu K, Tang K. Optimal workpiece setup for time-efficient and energysaving five-axis machining of freeform surfaces. Journal of Manufacturing Science and Engineering, 2017, 139(5): 051003

[22] Wasif M, Iqbal S A, Ahmed A, Optimization of simplified grinding wheel geometry for the accurate generation of end-mill cutters using the five-axis CNC grinding process. International Journal of Advanced Manufacturing Technology, 2019, 105(10): 4325–4344

[23] Chen Z C, Wasif M. A generic and theoretical approach to programming and post-processing for hypoid gear machining on multi-axis cnc face-milling machines. International Journal of Advanced Manufacturing Technology, 2015, 81(1–4): 135–148

[24] Wasif M, Chen Z C. An accurate approach to determine the cutting system for the face milling of hypoid gears. International Journal of Advanced Manufacturing Technology, 2016, 84(9–12): 1873–1888

[25] Wasif M, Chen Z C, Hasan S M. Determination of cutter-head geometry for the face-milling of hypoid gears. International Journal of Advanced Manufacturing Technology, 2015, 86(9): 3081–3090

[26] Rababah M, Wasif M, Omari M, A novel approach to profile-milling for end-mill flutes in 4-axis CNC turn-milling machines, Part II: Simulation and verification. International Review of Mechanical Engineering, 2019, 13(3): 203–211

[27] Rababah M, Wasif M, Omari M, A novel approach to profile-milling for end-mill flutes in 4-axis CNC turn-milling machines, Part I: Mathematical modeling. International Review of Mechanical Engineering, 2019, 13(2): 133–141

[28] Yan G, Chen H, Zhang X, A dimension-driven adaptive programming for tool-path planning and post-processing in 5-axis form milling of hyperboloidal-type normal circular-arc gears. International Journal of Advanced Manufacturing Technology, 2020, 106(7–8): 2735–2746

RIGHTS & PERMISSIONS

Higher Education Press