This paper presents a method of determining the shape of the surface swept by a tool that follows a 5-axis tool path for machining curved surfaces. The method is based on discretizing the tool into pseudo-inserts and identifying imprint points using a modified principle of silhouettes. An imprint point exists for each pseudo-insert, and the piecewise linear… (More)
In this paper, we give a detailed mathematical understanding of flank milling with flat end cutters, which we use to develop a method for milling with such a cutter. This method slides the cutter along two rails, providing two points of contact on the surface.
This paper presents a positioning strategy for flank milling ruled surfaces. It is a modification of a positioning method developed by Bedi et al. . A cylindrical cutting tool is initially positioned tangential to the two boundary curves on a ruled surface. Optimization is used to move these tangential points to different curves on the ruled surface to… (More)
This paper presents a method of determining the shape of the surface swept by a generalized milling tool that follows a 5-axis tool path for machining curved surfaces. The method is a generalization of an earlier technique for toroidal tools that is based on identifying grazing points on the tool surface. We present a new proof that the points constructed… (More)
Multi-point machining (MPM) is a tool positioning technique used for finish machining of sculptured surfaces. In this technique the desired surface is generated at more than one point on the tool. The concept and viability of MPM was developed by the current authors in previous works. However, the method used to generate the multi-point tool positions was… (More)
Many engineering objects have surfaces that are critical to their performance. Analysis codes are used to design these surfaces for efficient performance. The iterative procedure of design followed by analysis requires the ability to generate and modify such surfaces rapidly. In the work described in the paper, surfaces which blend together bifurcated… (More)
Curvature matching for 5-axis surface machining has been plagued by the complexity of the task. As a result the current tool positioning strategies are likewise computationally complicated. Gouging the surface has been the main concern and has presented the greatest dif®culty in the algorithms. Some of the methods perform exhaustive searches of the surface… (More)
This paper presents and compares methods of error metrics used to measure the error for the flank milling of a machined ruled surface. The aim of this work is to propose a new scheme for error approximation that is easy to implement and gives better error assessment when using optimization techniques to determine tool position. We propose using as the error… (More)