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Title: Interference-free tool path generation for 5-axis sculptured surface machining using rational Bézier motions of a flat-end cutter
Authors: Zhang, W.
Zhang, Y.F. 
Ge, Q.J.
Keywords: 5-axis tool path generation
Dual quaternion
Effective cutting shape
Interference avoidance
Rational Bézier motion
Scallop height
Sculptured surface machining
Issue Date: 1-Oct-2005
Citation: Zhang, W., Zhang, Y.F., Ge, Q.J. (2005-10-01). Interference-free tool path generation for 5-axis sculptured surface machining using rational Bézier motions of a flat-end cutter. International Journal of Production Research 43 (19) : 4103-4124. ScholarBank@NUS Repository.
Abstract: This paper presents a new approach that uses rational Bézier motions to generate 5-axis tool path for sculptured surface machining (finish cut) with a flat-end cutter. By using dual quaternion to represent a spatial displacement, the representation of kinematic motions for the cutter bottom circle of the flat-end cutter is formulated. Based on that, a new approach for tool path generation using rational Bézier cutter motions is described, in which key issues such as interference avoidance and surface accuracy requirement are addressed. First, a set of cutter contact points on an iso-parametric curve of the designed surface is obtained based on a given fitting tolerance. The associated cutter locations (CLs) are then obtained by finding the suitable cutter orientations that avoid any gouging. The conversion from the CLs to dual quaternion representation is carried out and the rational Bézier dual quaternion curve for cutter motion is generated. The entire tool path is therefore established based on the cutter undergoing the rational Bézier motion. Next, the whole tool path is checked to find (1) if there is any interference between the cutter and the designed surface, and (2) whether the deviation between the surface generated by the cutter motion and the designed surface is larger than the given tolerance. The problematic CLs, which cause either gouging or accuracy problem, are then modified. The process of tool path checking → CLs modification → tool path regeneration continues until the whole tool path is interference-free and satisfies the accuracy requirement. Furthermore, a more accurate representation of the effective cutting shape is proposed, which is used to evaluate the scallop height between adjacent tool paths. A method for constructing the adjacent tool path has been developed by considering the allowable scallop height. Finally, computer implementation and an illustrative example are presented to demonstrate the efficacy of the approach. © 2005 Taylor & Francis Group Ltd.
Source Title: International Journal of Production Research
ISSN: 00207543
DOI: 10.1080/00207540500168188
Appears in Collections:Staff Publications

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