An Optimization Post-Processing Module For Complex Tool-Tip Milling Operations

Luc Baron, Luc Rolland

Research output: Book/ReportOther report

Abstract

This paper presents an optimization post-processing module allowing to improve and to optimize tool-tip milling operations. Moreover, this module verifies and insures milling feasibility of a complex tri-dimensional shape. During such situations, the tool is in contact with the workpiece through a point located on its ball-end mill. Knowing that a relatively large variation of the tool orientation does not necessarily change the resulting workpiece geometry, then the postprocessing
module can be formulated as an optimization problem. The tool orientation is computed to be as close as possible to our preferred orientation together with its joints as far as possible to the joint limits, and obviously, subject that the tool-tip is following the required
trajectory. The module has been implemented for the Huron KX8-Five milling centre. Several surface shapes have been post-processed and verified in simulations with VERICUT, among which four parts have effectively been machined. Our optimal module produced a CAM program
which could then be transferred into a CNC milling machine and this program succeeded in machining a complex workpiece which would normally prove unfeasible with a classical approach which usually maintains the tool normal to the surface without exceeding the joint limits.
Original languageEnglish
Place of PublicationSt. John's, Newfoundland
PublisherMemorial University of Newfoundland
Number of pages19
Publication statusPublished - 2014
Externally publishedYes

Fingerprint

Processing
Milling machines
Computer aided manufacturing
Machining
Geometry

Keywords

  • post-processor
  • five-axes milling
  • joint-limits avoidance
  • inverse kinematics
  • redundancy resolution

Cite this

Baron, L., & Rolland, L. (2014). An Optimization Post-Processing Module For Complex Tool-Tip Milling Operations. St. John's, Newfoundland: Memorial University of Newfoundland.
Baron, Luc ; Rolland, Luc. / An Optimization Post-Processing Module For Complex Tool-Tip Milling Operations. St. John's, Newfoundland : Memorial University of Newfoundland, 2014. 19 p.
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abstract = "This paper presents an optimization post-processing module allowing to improve and to optimize tool-tip milling operations. Moreover, this module verifies and insures milling feasibility of a complex tri-dimensional shape. During such situations, the tool is in contact with the workpiece through a point located on its ball-end mill. Knowing that a relatively large variation of the tool orientation does not necessarily change the resulting workpiece geometry, then the postprocessingmodule can be formulated as an optimization problem. The tool orientation is computed to be as close as possible to our preferred orientation together with its joints as far as possible to the joint limits, and obviously, subject that the tool-tip is following the requiredtrajectory. The module has been implemented for the Huron KX8-Five milling centre. Several surface shapes have been post-processed and verified in simulations with VERICUT, among which four parts have effectively been machined. Our optimal module produced a CAM programwhich could then be transferred into a CNC milling machine and this program succeeded in machining a complex workpiece which would normally prove unfeasible with a classical approach which usually maintains the tool normal to the surface without exceeding the joint limits.",
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Baron, L & Rolland, L 2014, An Optimization Post-Processing Module For Complex Tool-Tip Milling Operations. Memorial University of Newfoundland, St. John's, Newfoundland.

An Optimization Post-Processing Module For Complex Tool-Tip Milling Operations. / Baron, Luc; Rolland, Luc.

St. John's, Newfoundland : Memorial University of Newfoundland, 2014. 19 p.

Research output: Book/ReportOther report

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AU - Rolland, Luc

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N2 - This paper presents an optimization post-processing module allowing to improve and to optimize tool-tip milling operations. Moreover, this module verifies and insures milling feasibility of a complex tri-dimensional shape. During such situations, the tool is in contact with the workpiece through a point located on its ball-end mill. Knowing that a relatively large variation of the tool orientation does not necessarily change the resulting workpiece geometry, then the postprocessingmodule can be formulated as an optimization problem. The tool orientation is computed to be as close as possible to our preferred orientation together with its joints as far as possible to the joint limits, and obviously, subject that the tool-tip is following the requiredtrajectory. The module has been implemented for the Huron KX8-Five milling centre. Several surface shapes have been post-processed and verified in simulations with VERICUT, among which four parts have effectively been machined. Our optimal module produced a CAM programwhich could then be transferred into a CNC milling machine and this program succeeded in machining a complex workpiece which would normally prove unfeasible with a classical approach which usually maintains the tool normal to the surface without exceeding the joint limits.

AB - This paper presents an optimization post-processing module allowing to improve and to optimize tool-tip milling operations. Moreover, this module verifies and insures milling feasibility of a complex tri-dimensional shape. During such situations, the tool is in contact with the workpiece through a point located on its ball-end mill. Knowing that a relatively large variation of the tool orientation does not necessarily change the resulting workpiece geometry, then the postprocessingmodule can be formulated as an optimization problem. The tool orientation is computed to be as close as possible to our preferred orientation together with its joints as far as possible to the joint limits, and obviously, subject that the tool-tip is following the requiredtrajectory. The module has been implemented for the Huron KX8-Five milling centre. Several surface shapes have been post-processed and verified in simulations with VERICUT, among which four parts have effectively been machined. Our optimal module produced a CAM programwhich could then be transferred into a CNC milling machine and this program succeeded in machining a complex workpiece which would normally prove unfeasible with a classical approach which usually maintains the tool normal to the surface without exceeding the joint limits.

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Baron L, Rolland L. An Optimization Post-Processing Module For Complex Tool-Tip Milling Operations. St. John's, Newfoundland: Memorial University of Newfoundland, 2014. 19 p.