Abstract
The machining industry must maximize the machine tool utilization for its efficient and effective usage. Determining a feasible workpiece location is one of the significant tasks performed in an iterative way via machining simulations. The maximum utilization of five-axis machine tools depends upon the cutting system’s geometry, the configuration of the machine tool, and the workpiece’s location. In this research, a mathematical model has been developed to determine the workpiece’s feasible location in the five-axis machine tool for avoiding the number of iterations, which are usually performed to eliminate the global collision and axis limit errors. In this research, a generic arrangement of the five-axis machine tool has been selected. The mathematical model of postprocessor has been developed by using kinematic modeling methods. The machine tool envelopes have been determined using the post-processor and axial limit. The tooltip reachable workspace is determined by incorporating the post-processor, optimal cutting system length, and machining envelope, thereby further developing an algorithm to determine the feasible workpiece setup parameters accurately. The algorithm’s application has been demonstrated using an example. Finally, the algorithm is validated for feasible workpiece setup parameters in a virtual environment. This research is highly applicable in the industry to eliminate the number of iterations performed for the suitable workpiece setup parameters.
Similar content being viewed by others
References
Altintas Y. Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Calibrations and CNC Design. Cambridge: Cambridge University Press, 2000
Bohez E L J. Five axis milling machine tool kinematic chain design and analysis. International Journal of Machine Tools and Manufacture, 2002, 42(4): 505–520
Stanislav S M, Weerachai A. Advance Numerical Method to Optimize Cutting Operations of Five-Axis Milling Machines. Berlin: Springer, 2007
Lee Y S. Admissible tool orientation control of gouging avoidance for 5-axis complex surface machining. Computer-Aided Design, 1997, 29(7): 507–521
Lo C. Efficient cutter-path planning for five axis surface machining with a flat-end cutter. Computer-Aided Design, 1999, 31(9): 557–566
Gray P, Bedi S, Ismail F. Rolling ball method for 5-axis surface machining. Computer-Aided Design, 2003, 35(4): 347–357
Gray P, Bedi S, Ismail F. Arc-intersection method for 5-axis tool positioning. Computer-Aided Design, 2005, 37(7): 663–674
Choi B K, Park J W, Jun C S. Cutter location data optimization in 5-axis surface machining. Computer-Aided Design, 1993, 25(6): 377–386
Jensen C G, Red W E, Pi J. Tool selection for five-axis curvature matched machining. Computer-Aided Design, 2002, 34(3): 251–266
She C, Chang C. Design of a generic five-axis postprocessor based on generalized kinematics model of machine tool. International Journal of Machine Tools and Manufacture, 2007, 47(3–4): 537–545
Jung Y H, Lee D W, Kim J S, et al. NC postprocessor for 5-axis milling machine of table rotating/tilting type. Journal of Materials Processing Technology, 2002, 130–131: 641–646
Chen L. Kinematics modelling and post processing method of five axis CNC machine. Proceedings of the 2009 First International Workshop on Education Technology and Computer Science, 2009, 1: 300–303
Affouard A, Duc E, Lartigue C, et al. Avoiding 5-axis singularities using tool path deformation. International Journal of Machine Tools and Manufacture, 2004, 44(4): 415–425
Munlin M, Makhanov S S, Bohez E L J. Optimization of rotations of a five-axis milling machine near stationary points. Computer-Aided Design, 2004, 36(12): 1117–1128
Anotaipaiboon W, Makhanov S S, Bohez E L J. Optimal setup for five-axis machining. International Journal of Machine Tools and Manufacture, 2006, 46(9): 964–977
Chen Z C, Ahmed A. A precise approach for the determination of the setup parameters to utilize maximum workspace of five-axis CNC machine tools. International Journal of Advanced Manufacturing Technology, 2016, 85(9–12): 2297–2311
Duong T, Rodriguez-Ayerbe P, Lavernhe S, et al. Contour error pre-compensation for five-axis high speed machining: Offline gain adjustment approach. International Journal of Advanced Manufacturing Technology, 2019, 100(9–12): 3113–3125
Sepahi-Boroujeni S, Mayers J R R, Khameneifar F. Repeatability of on-machine probing by a five-axis machine tool. International Journal of Advanced Manufacturing Technology, 2020, 152: 103544
Lin Z, Fu J, Shen H, et al. On the workpiece setup optimization for five-axis machining with RTCP function. International Journal of Advanced Manufacturing Technology, 2014, 74(1–4): 187–197
Pessoles X, Landon Y, Segonds S, et al. Optimisation of workpiece setup for continuous five-axis milling: Application to a five-axis BC type machining centre. International Journal of Advanced Manufacturing Technology, 2013, 65(1–4): 67–79
Xu K, Tang K. Optimal workpiece setup for time-efficient and energysaving five-axis machining of freeform surfaces. Journal of Manufacturing Science and Engineering, 2017, 139(5): 051003
Wasif M, Iqbal S A, Ahmed A, et al. Optimization of simplified grinding wheel geometry for the accurate generation of end-mill cutters using the five-axis CNC grinding process. International Journal of Advanced Manufacturing Technology, 2019, 105(10): 4325–4344
Chen Z C, Wasif M. A generic and theoretical approach to programming and post-processing for hypoid gear machining on multi-axis cnc face-milling machines. International Journal of Advanced Manufacturing Technology, 2015, 81(1–4): 135–148
Wasif M, Chen Z C. An accurate approach to determine the cutting system for the face milling of hypoid gears. International Journal of Advanced Manufacturing Technology, 2016, 84(9–12): 1873–1888
Wasif M, Chen Z C, Hasan S M. Determination of cutter-head geometry for the face-milling of hypoid gears. International Journal of Advanced Manufacturing Technology, 2015, 86(9): 3081–3090
Rababah M, Wasif M, Omari M, et al. A novel approach to profile-milling for end-mill flutes in 4-axis CNC turn-milling machines, Part II: Simulation and verification. International Review of Mechanical Engineering, 2019, 13(3): 203–211
Rababah M, Wasif M, Omari M, et al. A novel approach to profile-milling for end-mill flutes in 4-axis CNC turn-milling machines, Part I: Mathematical modeling. International Review of Mechanical Engineering, 2019, 13(2): 133–141
Yan G, Chen H, Zhang X, et al. A dimension-driven adaptive programming for tool-path planning and post-processing in 5-axis form milling of hyperboloidal-type normal circular-arc gears. International Journal of Advanced Manufacturing Technology, 2020, 106(7–8): 2735–2746
Acknowledgements
The funding of the research project was provided by NED University of Engineering and Technology, Pakistan.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Ahmed, A., Wasif, M., Fatima, A. et al. Determination of the feasible setup parameters of a workpiece to maximize the utilization of a five-axis milling machine. Front. Mech. Eng. 16, 298–314 (2021). https://doi.org/10.1007/s11465-020-0621-3
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11465-020-0621-3