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Principle and Application of the Ball End Mill Tool Radius Compensation for NURBS Curve Swept Surfaces Based on 3-Axis CNC Milling Machines

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Abstract

Common 3-axis CNC milling machines are generally equipped with 2D tool radius compensation (2D-TRC), which can realize TRC function for the contours in three basic planes when flat end mills are used. The 2D-TRC function makes engineers to program according to the actual contour of a part, and avoids over-cut phenomenon. Unfortunately, the 2D-TRC is unsuitable for ball end mills (BEMs), especially in the situation of milling complex curves or surfaces. In this work, a new TRC named BEM-TRC is used for milling NURBS curve swept surfaces using BEMs based on 3-axis CNC milling machines. In BEM-TRC, the TRC of a BEM involves radial and axial compensation. The cutting point (CP), which is the tangent point between a BEM and a NURBS curve, is considered as a calculation basis point. After obtaining a CP on a NURBS curve using the equi-arc length bisection interpolation method, the cutter center point of a BEM is calculated through offsetting the CP the radius (r) distance of the BEM along its normal vector. Then the cutter location point of the BEM can be obtained according to the cutter center point. The CNC finishing program corresponding to the cutter location point can be obtained using Matlab software. The simulation based on VERICUT and machining based on a 3-axis milling machine verifies the effectiveness of the BEM-TRC. The over-cut phenomenon is avoided successfully when the BEM-TRC is used.

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Acknowledgements

This project is supported by National Natural Science Foundation of China (Grant no. 51465030), Employee innovation subsidy fund project of All China Federation of Trade Unions, Open project of State Key Laboratory of Advanced Welding and Joining (AWJ-21Z02), Gansu Science and Technology Planning Project (20YF8GA033, 17YF1GA018, 17CX1JA117, and 18JR3RA132), Western Young Scholars of Chinese Academy of Sciences, Lanzhou Talent Innovation and Entrepreneurship Project (2020-RC-120, 2019-RC-102, and 2018-RC-108), Longyuan Youth Innovative and Entrepreneurial Talents Project, Foundation of A Hundred Youth Talents Training Program of Lanzhou Jiaotong University, and Gansu Provincial Employee Technology Innovation Subsidy Fund Project.

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Authors and Affiliations

  1. School of Mechatronic Engineering, Lanzhou Jiaotong University, Lanzhou, 730010, China

    Zhaoqin Wang, Xiaorong Wang, Xiaoqin Liu, Yusen Wang & Chengyu Li

  2. Key Laboratory of System Dynamics and Reliability of Rail Transport Equipment of Gansu Province, Lanzhou Jiaotong University, Lanzhou, 730010, China

    Zhaoqin Wang & Xiaorong Wang

  3. State Key Laboratory of Advanced Processing and Recycling of Nonferrous Metals, Lanzhou University of Technology, Lanzhou, 730050, China

    Zhaoqin Wang & Xiaorong Wang

  4. State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin, 150001, China

    Tiesong Lin & Peng He

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  1. Zhaoqin Wang
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  2. Xiaorong Wang
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Correspondence to Zhaoqin Wang or Xiaorong Wang.

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Wang, Z., Wang, X., Liu, X. et al. Principle and Application of the Ball End Mill Tool Radius Compensation for NURBS Curve Swept Surfaces Based on 3-Axis CNC Milling Machines. Int. J. Precis. Eng. Manuf. 22, 1517–1526 (2021). https://doi.org/10.1007/s12541-021-00555-5

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  • DOI: https://doi.org/10.1007/s12541-021-00555-5

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