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An accurate surface error optimization for five-axis machining of freeform surfaces

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Abstract

This paper presents an accurate surface error interpolation algorithm for five-axis machining of freeform surfaces. One of the most important steps in the interpolation process is to calculate the next cutter contact (CC) point according to the present one. In this paper, the next CC point is calculated by an accurate chord evaluation method. This method is developed based on the cutting simulation process, which can be vividly described as firstly planting dense grasses on the tool path curve and then cutting them when the tool moves by. The left lengths of the grasses either positive or negative are considered to be the machining error. The method is accurate also because the tool geometry and the tool orientation changes during five-axis machining are taken into consideration. With this method, the chord errors between CC points are controlled uniform along the tool path. The proposed interpolation algorithm is compared with the commercial CAM systems like PowerMILL and UG. The results show that the proposed algorithm can significantly reduce the number of cutter locations meanwhile confine the chord error. A real cutting experiment is implemented, and the result indicates its promising value in industrial applications.

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Authors and Affiliations

  1. The State Key Lab of Fluid Power Transmission and Control, Department of Mechanical Engineering, Zhejiang University, Hangzhou, 310027, China

    Zhiwei Lin, Jianzhong Fu, Hongyao Shen & Wenfeng Gan

Authors
  1. Zhiwei Lin
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  2. Jianzhong Fu
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  3. Hongyao Shen
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  4. Wenfeng Gan
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Correspondence to Jianzhong Fu.

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Lin, Z., Fu, J., Shen, H. et al. An accurate surface error optimization for five-axis machining of freeform surfaces. Int J Adv Manuf Technol 71, 1175–1185 (2014). https://doi.org/10.1007/s00170-013-5549-x

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  • DOI: https://doi.org/10.1007/s00170-013-5549-x

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