In this paper, we present a geometric algorithm of finding the maximal cutter for 2-D milling operations. Our algorithm works not only for the common closed pocket problem, but also for the general 2-D milling problems with open edges. We define the general 2-D milling process in terms of a “target region” to be machined and an “obstruction region” that should not intersect with the cutter duri...

Geometric algorithms for computing cutter engagement functions in 2.5D milling operations. ABSTRACT Cutter engagement is a measure that describes what portion of the cutter is involved in machining at a given instant of time. During profile milling of complex geometries, cutter engagement varies significantly along the cutter path. Cutter engagement information helps in determining the efficien...

In micro-milling, cutting forces generate non-negligible tool deflection, which has a significant influence on the machining process and on workpiece accuracy. This paper investigates the tool deflection during micro-milling and its effect on cutting force and surface generation. The distribution of cutting forces acting on the tool is calculated with a mathematical model that considers tool el...

The chatter is one of the major limitations of the productivity in the ball end milling process. It affects the surface roughness, the dimensional accuracy and the tool life. The aim of this research is to propose the new system to detect the chatter during the ball end milling process by using the wavelet transform. The proposed method is implemented on the 5-axis CNC machining center and the ...

In a 3D free-form CAM system, a series of intermediate shape models for machining are required as the references of NC programming. The safety and efficiency of the machining greatly depend on the geometric relation between these intermediate shape models. However current CAM systems lack the function of automatic generation of the appropriate series of these shape models. In this paper, a new ...

In this paper, a method integrating NC decoding and solid milling simulation to solve this problem is proposed. A modified Z-Map computational algorithm is adopted and it directly uses straight line and arc interpolation algorithms to calculate mesh position and Z coordinates of tool scanning surface according to tool path and initial tool scanning boundary in reducing the long computation time...

The most common machining methods in machining are turning, milling, drilling and grinding. Significant studies are conducted in machining industry and academic circles in order to measure the cutting force during these processes. This study includes a review of these studies, a categorization of similar ones and detailed information about measurement systems. Through the review of studies, we ...

5-Axis machining has been widely used in manufacturing of complex ruled geometries in automobile, aerospace, energy, and mould industries. Compared with traditional 3-axis machining, this machining operation offers better shaping capability and productivity with additional degrees of freedom in the tool motion. Tool path planning is a challenging task in most 5-axis machining operations, with t...

Abrasive machining is a widely employed finishing process for different materials such as metals, ceramics, glass, rocks, etc to achieve close tolerances and good dimensional accuracy and surface integrity. High efficiency abrasive machining is one of the important techniques of advanced manufacture. Combined with raw and finishing machining, it can attain high material removal rate like turnin...

Zigzag pocket machining (or 2D-milling) plays an important role in the manufacturing industry. The objective is to minimize the number of tool retractions in the zigzag machining path for a given pocket (i.e., a planar domain). We give an optimal linear time dynamic programming algorithm for simply connected pockets, and a linear plus O(1) time optimal algorithm for pockets with h holes. If the...