Tool orientations’ generation and nonlinear error control based on complex surface meshing

• Published in: International journal of advanced manufacturing technology Vol. 105; no. 10; pp. 4279 - 4288
• Main Authors: Hong, Xinyu, Hong, Rongjing, Lin, Xiaochuan
• Format: Journal Article
• Language: English
• Published: London Springer London 01.12.2019; Springer Nature B.V
• Subjects: CAE) and Design; Computer-Aided Engineering (CAD; Cutters; Engineering; Error analysis; Five axis; Industrial and Production Engineering; Interpolation; Machine shops; Machining; Mechanical Engineering; Media Management; Meshing; Nonlinear analysis; Nonlinear control; Orientation; Original Article; Surface finish; Surface properties; Five-axis machining; Complex surface; Tool orientations
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-019-04480-w

Tool orientations’ planning of five-axis machining is a significant factor for impacting surface quality and overall machining accuracy of complex-curved surface parts. This paper particularly describes a practical method of tool orientation’s generation for ball cutters commonly used in complex surface finish machining. Based on the method of triangular meshing in surface, the points and the normal vectors are respectively extracted from the surface with unknown parameters. Each obtained normal vector is translated by Rodrigues’ rotational motion in space into the tool orientation for the ball cutter. The generated tool orientation is simple to be adjusted and can effectively avoid problems such as overcut and interference during machining. In addition, by analyzing the nonlinear error between adjacent tool orientations in machining, an interpolation is proposed approach to reduce the rotational error angle and guarantee the continuity of trajectory. After actual processing, the highlights of this method are verified.