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Tool orientations’ generation and nonlinear error control based on complex surface meshing

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Abstract

Tool orientations’ planning of five-axis machining is a significant factor for impacting surface quality and overall machining accuracy of complex-curved surface parts. This paper particularly describes a practical method of tool orientation’s generation for ball cutters commonly used in complex surface finish machining. Based on the method of triangular meshing in surface, the points and the normal vectors are respectively extracted from the surface with unknown parameters. Each obtained normal vector is translated by Rodrigues’ rotational motion in space into the tool orientation for the ball cutter. The generated tool orientation is simple to be adjusted and can effectively avoid problems such as overcut and interference during machining. In addition, by analyzing the nonlinear error between adjacent tool orientations in machining, an interpolation is proposed approach to reduce the rotational error angle and guarantee the continuity of trajectory. After actual processing, the highlights of this method are verified.

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Funding

This work was supported by the National Natural Science Foundation of China (Grant No. 51635003), and the Postgraduate Research & Practice Innovation Program of Jiangsu Province (Grant No.KYCX18_1092).

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Authors and Affiliations

  1. School of Mechanical and Power Engineering, Nanjing Tech University, No.30, Puzhu Southern Road, Pukou District, Nanjing, 211816, Jiangsu, China

    Xinyu Hong, Rongjing Hong & Xiaochuan Lin

  2. Jiangsu Key Laboratory of Digital Manufacturing for Industrial Equipment and Control Technology, Nanjing Tech University, No.30, Puzhu Southern Road, Pukou District, Nanjing, 211899, Jiangsu, China

    Xinyu Hong, Rongjing Hong & Xiaochuan Lin

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  1. Xinyu Hong
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  2. Rongjing Hong
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  3. Xiaochuan Lin
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Correspondence to Rongjing Hong or Xiaochuan Lin.

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Hong, X., Hong, R. & Lin, X. Tool orientations’ generation and nonlinear error control based on complex surface meshing. Int J Adv Manuf Technol 105, 4279–4288 (2019). https://doi.org/10.1007/s00170-019-04480-w

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  • DOI: https://doi.org/10.1007/s00170-019-04480-w

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