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Proceedings of CAD'14, 2014, 186-188
Optimization of Barrel Cutter for Five-axis Flank-milling based on Approximation of Tool Envelope Surface

Dongqing Yan, Dinghua Zhang, Ming Luo, Northwestern Polytechnical University

Abstract. The machined surface in flank milling is formed by the swept envelope of the cutter surface. The true machining errors are the deviations between the cutter envelope surface and design surface. Recently increasing attention was drawn to non-single curvature tool which has different curvatures in different positions and gestures. Thus, the cutter envelope surface can approach to the design surface as perfect as possible by adjusting the tool position and gesture at contact point. As a result, the material removal rate and the precision can be increased at the same time. Chaves-Jacob et al proposed a novel approach that optimizes the tool shape for a given trajectory-surface pair to reduce the interferences. Gong et al determined the optimum CL by least squares (LS) fitting of a spatial line to a series of post-processed point data. This method could smooth the error distribution in the normal section along the feed direction, but it can’t control the errors between the cutter envelope surface and design surface in regions near the contact point. Wang et al proposed a flank milling tool positioning method based on an offset point of the designed surface with the excess error is nearly equal to the allowed error. Most work focus on the optimization of tool paths from the perspective of increasing machining accuracy, avoiding interference with fixed cutter. Only a few works pay attention to increase the machining precision by approximating the cutter envelope surface to designed surface.

Keywords. Barrel cutter, envelope surface, five-axis milling

DOI: 10.14733/cadconfP.2014.186-188