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Research Papers

Computing Cutter Engagement Values in Milling Tessellated Free-Form Surfaces

[+] Author and Article Information
Zhiyang Yao1

Department of IELM, HKUST, Hong Kong SARzyyaomae@gmail.com

Ajay Joneja

Department of IELM, HKUST, Hong Kong SARjoneja@ust.hk

1

Corresponding author.

J. Comput. Inf. Sci. Eng 10(4), 041005 (Dec 17, 2010) (6 pages) doi:10.1115/1.3527074 History: Received December 22, 2006; Revised July 04, 2010; Published December 17, 2010; Online December 17, 2010

High speed milling (HSM) has great potential use in die/mold cutting, but traditional machining plans do exploit HSM capabilities effectively. An important consideration in HSM is to limit cutting force variations, and one way to do so is to reduce cutter-workpiece engagement (CWE) variations. CWE is measured as the area of the tool instantaneously engaged with the part. Estimating CWE as a function of the tool path requires repeated, expensive computations. This paper develops algorithms for a discretized computational model to make CWE computations for arbitrary shaped parts.

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Copyright © 2010 by American Society of Mechanical Engineers
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Figures

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Figure 1

Plane: z=0; cylinder: x2+y2=R2; sphere: x2+y2+z2=R2; cone: axis along Z

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Figure 2

Converting planar CWE region into polygon for computing area

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Figure 3

(a) Lune with lunar angle=a and surface area=2R2a and (b) semilune

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Figure 4

Computing area of a simple polygon on a sphere

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Figure 5

Different cases of computing polygon area on a sphere

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Figure 6

Computing CWE on tapered tools

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Figure 7

A mold cavity for a toy car

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Figure 8

Geometry of the layer used for example part

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Figure 9

CWE area (red) in some intermediate positions of the cutting

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Figure 10

CWE changes as cutter moves along path (computed at 1 mm steps)

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