Skip to main content
SpringerLink
Log in

Milling path planning for helical surface copper electrodes

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Milling has the characteristics of flexibility and versatility, and can largely reduce the production cycle of customized tools. This study aims to mill helical surfaces of uniform roughness with universal tools in four-axis CNC machine tools through designing the optimal milling path. The transverse profile of the involute gear is modeled by the analytical method and the equidistant profile of the transverse profile is established by using the principle of normal offset to provide a theoretical tool position for tool paths. Aiming at the problem of unequal adjacent line spacing generated in the determination of the number of feed lines based on a constant angle, a determination method of the number of feed lines based on a constant arc length is proposed. In this method, according to the principle of calculus, the arc length of the involute curve is calculated to determine the proper number of feed lines which allows the scallop height to be approximately uniformly distributed on the tooth surface. In milling experiments, the processing efficiencies of LRTSLBL milling and LRTSTBT milling were confirmed and the peak of pitch under a small volume of tool wear was avoided by LRTSLBL milling. Importantly, the skip tooth machining test by LRTSTBT milling confirmed the cause for pitch peak and provided the basis for pitch error compensation.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25

Similar content being viewed by others

References

  1. Deng XQ, Wang SS, Youssef H, Qian LM, Liu YC (2020) Study on the influence of key design parameters on lubrication characteristics of a novel gear system applying taguchi method. Struct Multidiscip O 62 (5):1–15

    Article  Google Scholar 

  2. Deng XQ, Wang SS, Hammi Y, Qian LM, Liu YCA (2020) Combined experimental and computational study of lubrication mechanism of high precision reducer adopting a worm gear drive with complicated space surface contact. Tribol Int 106261:146

    Google Scholar 

  3. Yu B, Shi ZY, Lin JC (2017) Topology modification method based on external tooth-skipped gear honing. Int J Adv Manu Tech 92(9):4561–4570

    Article  Google Scholar 

  4. He FY, Shi ZY, Yu B (2018) Effects of tooth surface modification on planar double-enveloping hourglass worm gear drives. J Adv Mech Des Syst 12(2):JAMDSM0040–JAMDSM0040

    Article  Google Scholar 

  5. Schmitz T, Davies M, Dutterer B, Ziegert J (2001) The application of high-speed cnc machining to prototype production. Int J Mach Tool Manu 41(8):1209–1228

    Article  Google Scholar 

  6. Suh SH, Jih WS, Hong HD, Chung DH (2001) Sculptured surface machining of spiral bevel gears with cnc milling. Int J Mach Tool Manu 41(6):833–850

    Article  Google Scholar 

  7. Suh S-H, Jung D-H, Lee S-W, Lee E-S (2003) Modelling, implementation, and manufacturing of spiral bevel gears with crown. Int J Adv Manu Tech 21(10-11):775–786

    Article  Google Scholar 

  8. Kawasaki K, Tsuji I, Abe Y, Gunbara H (2010) Manufacturing method of large-sized spiral bevel gears in cyclo-palloid system using multi-axis control and multi-tasking machine tool. In: Pro Intl Conf gears, Garching, Germany, vol 1, pp 337–348

  9. Kawasaki K, Tsuji I, Gunbara H (2016) Manufacturing method of double-helical gears using cnc machining center. P I MECH ENG C-J MEC 230(7-8):1149–1156

    Article  Google Scholar 

  10. Kawasaki K, Tsuji I, Gunbara H (2014) Manufacturing method of double helical gears using multi-axis control and multitasking machine tool. In: Int. Gear Conf, pp 86–95

  11. Álvarez A, de Lacalle LL, Olaiz A, Rivero A (2015) Large spiral bevel gears on universal 5-axis milling machines: a complete process. Procedia Eng. 132:397–404

    Article  Google Scholar 

  12. Álvarez Á, Calleja A, Ortega N, De Lacalle LNL (2018) Five-axis milling of large spiral bevel gears: toolpath definition, finishing, and shape errors. Metals 8(5):353

    Article  Google Scholar 

  13. Teixeira AJ, Guingand M, de Vaujany JP (2013) Designing and manufacturing spiral bevel gears using 5-axis computer numerical control (cnc) milling machines. J Mech Design, 135(2)

  14. Bouquet J, Hensgen L, Klink A, Jacobs T, Klocke F, Lauwers B (2014) Fast production of gear prototypes–a comparison of technologies. Procedia CIRP 14:77–82

    Article  Google Scholar 

  15. Jiang JC, Stringer J, Xu X (2019) Support optimization for flat features via path planning in additive manufacturing. 3D Print Addit Manuf 6(3):171–179

    Article  Google Scholar 

  16. Jiang JC, Xu X, Stringer J (2019) Optimization of process planning for reducing material waste in extrusion based additive manufacturing. Robot Com-Int Manuf 59:317–325

    Article  Google Scholar 

  17. Malek O, Mielnik K, Martens K, Jacobs T, Bouquet J, Auwers W, Ten Haaf P, Lauwers B (2016) Lead time reduction by high precision 5-axis milling of a prototype gear. Procedia CIRP 46:440–443

    Article  Google Scholar 

  18. Hyatt G, Piber M, Chaphalkar N, Kleinhenz O, Mori M (2014) A review of new strategies for gear production. Procedia CIRP 14:72–76

    Article  Google Scholar 

  19. Glaser T, Körner T, Sapparth J, Wennmo M (2018) Hard machining of spur gears with the invomillingtm method. J Manu. Mater Process 2(3):44

    Google Scholar 

  20. Klocke F, Brumm M, Staudt J (2014) Quality and surface of gears manufactured by free form milling with standard tools. In: Pro. Intl Gear Conf., Lyon, France, pages 26–28

  21. Staudt J, Löpenhaus C, Klocke F (2017) Performance of gears manufactured by 5-axis milling. Gear Technol 3:58–65

    Google Scholar 

  22. Guo EK, Ren NF, Liu ZL, Zheng XT, Zhou CL (2019) Study on tooth profile error of cylindrical gears manufactured by flexible free-form milling. Int J Adv Manu Tech 103(9-12):4443– 4451

    Article  Google Scholar 

  23. de Souza AF, Käsemodel R B, Arias M, Marin F, Rodrigues AR (2019) Study of tool paths calculated by different commercial cam systems and influences on the real machining time and surface roughness for milling free-form geometries. J Braz Soc Mech Sci 41(9):363

    Article  Google Scholar 

  24. Bedi S, Mann S, Menzel C (2003) Flank milling with flat end milling cutters. Comput Aided Des 35(3):293–300

    Article  Google Scholar 

  25. Bouzakis K-D, Aichouh P, Kyriakos E (2003) Determination of the chip geometry, cutting force and roughness in free form surfaces finishing milling, with ball end tools. Int J Mach Tool Manu 43(5):499–514

    Article  Google Scholar 

  26. Chu CH, Chen JT (2006) Tool path planning for five-axis flank milling with developable surface approximation. Int J Adv Manu Tech 29(7-8):707

    Article  Google Scholar 

  27. Rao N, Ismail F, Bedi S (1997) Tool path planning for five-axis machining using the principal axis method. Int J Mach Tool Manu 37(7):1025–1040

    Article  Google Scholar 

  28. Takashi M (1999) An overview of offset curves and surfaces. Comput Aided Des 31(3):165–173

    Article  Google Scholar 

  29. Piegl LA, Tiller W (1999) Computing offsets of nurbs curves and surfaces. Comput Aided Des 31(2):147–156

    Article  Google Scholar 

  30. Nittler KM, Farouki RT (2016) A real-time surface interpolator methodology for precision cnc machining of swept surfaces. Int J Adv Manu Tech 83(1-4):561–574

    Article  Google Scholar 

  31. Xu JT, Sun YW, Zhang L (2015) A mapping-based approach to eliminating self-intersection of offset paths on mesh surfaces for cnc machining. Comput Aided Des 62:131–142

    Article  Google Scholar 

  32. Huang N, Jin YQ, Lu YA, Li XY, Wu SJ (2019) Plunge milling with constant scallop height by adaptively modifying the step interval for pocket wall. Int J Adv Manu Tech 101(1-4):203–208

    Article  Google Scholar 

  33. Jia ZY, Zhao XX, Ma JW, Chen SY, Qin FZ, Liu Z (2019) Toolpath generation in sub-regional processing with constraint of constant scallop-height at boundary for complex curved surface. Precis Eng 55:217–230

    Article  Google Scholar 

  34. Saikumar S, Shunmugam MS (2006) Parameter selection based on surface finish in high-speed end-milling using differential evolution. Mater Manu Process 21(4):341–347

    Article  Google Scholar 

  35. Litvin FL, Fuentes A (2004) Gear geometry and applied theory. Cambridge University Press, Cambridge

    Book  Google Scholar 

  36. Shchurov IA, Al-Taie LH (2017) Constant scallop-height tool path generation for ball-end mill cutters and three-axis cnc milling machines. Procedia Eng 206:1137–1141

    Article  Google Scholar 

  37. Balabokhin A, Tarbutton J (2017) Iso-scallop tool path building algorithm “based on tool performance metric” for generalized cutter and arbitrary milling zones in 3-axis cnc milling of free-form triangular meshed surfaces. J Manu Process 28:565–572

    Article  Google Scholar 

Download references

Acknowledgements

The authors would like to thank Zhongshan Mltor CNC Technology Co., Ltd. and Dongguan Xinghuo Gear Co., Ltd. for their active support in the preparation of this paper.

Funding

This document is the result of the research project funded by the National Natural Science Foundation of China(Grant No. 51775003).

Author information

Authors and Affiliations

  1. Beijing Engineering Research Center of Precision Measurement Technology and Instruments, Beijing University of Technology, No.100, Pingleyuan, Chaoyang District, 100124, Beijing, China

    Zhaoyao Shi, Zhipeng Feng, Ke Li, Jihua Ren & Peng Wang

  2. Zhongshan Mltor CNC Technology Co., Ltd., No.43, Keji West Rd, Torch Development Zone, 528437, Zhongshan City, Guangdong Province, China

    Shoujin Lin

  3. Dongguan Xinghuo Gear Co., Ltd, No.19, Baoshi Road, Tangxia Town, 523715, Dongguan City, Guangdong Province, China

    Aijun Tong

Authors
  1. Zhaoyao Shi
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Zhipeng Feng
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Shoujin Lin
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Aijun Tong
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Ke Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Jihua Ren
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Peng Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Peng Wang.

Ethics declarations

Conflict of interests

The authors declare no competing interests.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Shi, Z., Feng, Z., Lin, S. et al. Milling path planning for helical surface copper electrodes. Int J Adv Manuf Technol 114, 1031–1048 (2021). https://doi.org/10.1007/s00170-021-06886-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-06886-x

Keywords

Search

Navigation