• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.19 no.2
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• pp.251-259
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• 2010

It is presented in this study a new efficient intelligent machining strategy, which can be used to remove the uncut volume at the boundary region of curved surfaces caused by cutter interference. The geometric form definitions and recognition of topological features of the surface triangulation mesh are used to generate cutter paths along successive and interconnected steepest pathways, that minimize the cusp height left after flat end milling. In order to machine the uncut volume gradually, the z-map cutter centers are adjusted to avoid cutter interference for the 6 kinds of avoidance types. And then, the generative subsequent paths are sequenced to determine the second step cutter paths for the next uncut volume. For the 2 kinds of test models with convex and concave surface region, the implemented software algorithm is evaluated by investigating the residual swelling of uncut volume for each machining step.

• Journal of Korean Institute of Industrial Engineers
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• v.26 no.4
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• pp.325-335
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• 2000

Gouge-free tool-path generation is an important issue in mold & die machining and researches on cutter interference avoidance can be found in many articles. One of the various methods is construction of tool-offset surface of cutter-location (CL) surface on which the cutter-center point (CL-point) locates. Provided that the CL surface is represented in a suitable form, cutter-interference avoidance can be performed without the burden of computing CL data for every cutter-contact (CC) point. In the paper, various methods of constructing a CL surface in the z-map form are presented, where z-map is a special form of discrete nonparametric representation in which the height values at grid points on the xy-plane are stored as a 2D array z[i,j].

• Proceedings of the Korean Operations and Management Science Society Conference
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• 2000.04a
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• pp.389-392
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• 2000

Gouge-free tool-path generation is an important issue in mold & die machining and researches on cutter interference avoidance can be found in many articles. One of the various methods is construction of tool-offlet surface or cutter-location (CL) surface on which the cutter-center point (CL-point) locates. Provided that the CL surface is represented in a suitable form, cutter-interference avoidance can be performed without the burden of computing CL data for every cutter-contact (CC) point. In the paper, various methods of constructing a CL surface in the z-map form are presented, where z-map is a special form of discrete nonparametric representation in which the height values at grid points on the xy-plane are stored as a 2D array z［i,j］.

• Journal of Korean Institute of Industrial Engineers
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• v.19 no.3
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• pp.139-154
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• 1993

Cutter Interference(or part surface gouging) is one of the most critical problems in NC machining of sculptured surfaces. Presented in this paper is and algorithmic procedure that converts CC data obtained from a compound surface(several surfaces without topological relationship) into interference-free CL data. The interference handling procedure consists of following steps: (1) Z-map model is constructed from input surfaces. (2) Interference sources are detected using local properties of the sources. (3) Interference regions are completely identified based on global tests for neighboring CC points of the interference sources (4) Cutter paths are reconstructed after removing the CC data in interference regions, while avoiding any new interferences.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.2
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• pp.27-33
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• 2012

A marine propeller is designed for preventing cavitation priority. Cavitation is a phenomenon which is defined as the vibration or noise by dropping the pressure on the high-speed rotation of the propeller. There has to be a enough thrust on the low-speed rotation for preventing cavitation. Thus, it has to be considered in the increasing of the number of blade and the angle of wing to design the propeller. In addition, flow resistance will be increasing by narrowing the width between blades. So high quality surface roughness of the hub to minimize flow resistance is required. Interference problems with tool and neighboring surfaces often take place from this kind of characteristics of the propeller. During 5-Axis machining of these propellers, the excessive local interference avoidance, necessary to avoid interference, leads to inconsistency of cutter posture, low quality of machined surface. Therefore, in order to increase the surface quality, it is necessary to minimize the cutter posture changes and create a continuous tool path while avoiding interference. This study, by using a MC-space algorithm for interference avoidance and a MB-spline algorithm for continuous control, is intended to create a 5-Axis machining tool path with excellent surface quality. Also, an effectiveness is confirmed through a verification manufacturing.

• Proceedings of the Korean Operations and Management Science Society Conference
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• 1993.04a
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• pp.394-394
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• 1993

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.10 no.2
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• pp.1-8
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• 2011

5-axis NC machining has a good advantage of the accessibility of tool motion by adding two rotary axes. It offers numerous advantages such as expanding machining fields in parts of turbo machineries like impeller, propeller, turbine blade and rotor, reasonable tool employment and great reduction of the set-up process. However, as adding two rotary axes, it is difficult to choose suitable machining conditions in terms of cutter path and cutter posture at a cutter contact point. Therefore in this paper, it is proposed to decide suitable machining condition through an experimental method such as adopting various cutter paths, cutter postures types. Also, in order to increase the efficiency of 5-axis machining, it is necessary to minimize the cutter posture changes and create a continuous cutter path while avoiding interference. This study, by using an MC-space algorithm for interference avoidance and an MB-spline algorithm for continuous control, is intended to create a 5-axis machining cutter path with excellent surface quality and economic feasibility. finally, this study will verify the effectiveness of the suggested method through verification processing.

• Korean Journal of Computational Design and Engineering
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• v.7 no.1
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• pp.34-41
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• 2002

Five-axis NC machining, in general, is utilized in fabricating impellers, turbine blades, marine propellers that can be machined more effectively rather than three-axis machining. There have been many researches concerning tool interference avoidance, optimization of tool orientation. The C-space or Configuration-space was originated from the robotics area, which depicts interference-free joint-values in motion planning. In the paper we propose an optimizing scheme by which the maximum effective-radius of a face-milling cutter can be achieved for each CC(cutter-contact) point. Also the concept of a C-space for a CC point, the effective-radius map for 5-axis face-milling, and some illustrative examples of marine propeller machining, are presented.

• Proceedings of the Korean Operations and Management Science Society Conference
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• 1991.10a
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• pp.124-130
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• 1991

5-axis NC machining of sculptured surface using non-ballendmill cutters (eg. facemilling cutters) is widely used in the machining of turbine blades and marine propellers. Since there are more degrees of freedom in 5-axis machining than in 3-axis machining, generating "optimum" cutter paths and finding desirable cutter positions become very important in order for an efficient use of 5-axis NC machines. Also critical in 5-axis NC machining are collision avoidance, gouging checking, and efficient kinematic solutions. In this paper we discuss the above issues in generating 5-axis CL data. They are : kinematics modeling of NC machine; inverse kinematics solution; interference between machine component and surface; cutter gouging. A unique search method for obtaining optimal CL data is proposed. The proposed method has been successfully implemented in the machining of marine propellers on a dual 5-axis (ie, 9-axis) NC machine.C machine.

• Journal of Mechanical Science and Technology
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• v.18 no.5
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• pp.753-761
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• 2004

In this paper, an efficient method for generating 5-axis cutting data for a turbine blade is presented. The interference elimination of 5-axis cutting currently is very complicated, and it takes up a lot of time. The proposed method can generate an interference-free tool path, within an allowance range. Generating the cutting data just point to the cutting process and using it to obtain NC data by calculating the feed rate, allows us to maintain the proper feed rate of the 5-axis machine. This paper includes the algorithms for: (1) CL data generation by detecting an interference-free heel angle, (2) finding the optimal tool path interval considering the cusp-height, (3) finding the adaptive feed rate values for each cutter path, and (4) the inverse kinematics depending on the structure of the 5-axis machine, for generating the NC data.