5-Axis CNC Tool Path Generation Using Plane-Based Orientation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current CNC machine tools with 5 axes face challenges in achieving optimal surface quality and reducing tool wear due to irregular tool orientations and discontinuous rotary axis movements, leading to poor geometric accuracy and increased maintenance costs.
Innovation Solution
A method for generating control data that specifies tool paths based on position data of points on the surface, with the tool orientation aligned to a common plane perpendicular to the base body, avoiding unnecessary inclinations and ensuring precise tool alignment, thereby reducing tool wear and improving surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional tool path generation methods are used with 5-axis CNC machine tools, then complex geometries can be machined, but irregular tool orientations and discontinuous rotary axis movements occur leading to poor surface quality and increased tool wear
Solution Approach 1:
The patent transforms the tool path generation approach by changing the fundamental parameters from traditional point-by-point or curve-based methods to a plane-based methodology. By defining tool paths through planes characterized by normal vectors and intersection curves with the workpiece surface, the system achieves continuous and smooth tool orientations, eliminating the irregular movements that cause poor surface quality and excessive tool wear.
Solution Approach 2:
The patent implements dynamic adaptation of tool orientation by continuously adjusting the tool axis to remain perpendicular to the local surface plane during machining. This dynamic reorientation based on local surface geometry ensures smooth, continuous rotary axis movements while maintaining optimal cutting conditions, thereby improving surface quality and reducing tool wear compared to static or discrete orientation methods.
2Duration of action of moving object
If traditional tool path generation methods are used, then material removal can be performed, but discontinuous rotary axis movements occur leading to increased tool wear and maintenance costs
Solution Approach 1:
The patent fundamentally changes the tool path parameterization from traditional methods to a plane-based system where each tool path segment is defined by a plane's normal vector and its intersection curve with the workpiece surface. This parameter transformation ensures continuous and differentiable tool orientations, eliminating discontinuous rotary axis movements that cause tool wear, while simultaneously improving geometric accuracy through mathematically precise plane-surface intersections.
Solution Approach 2:
The patent replaces the mechanical approach of discrete tool orientation adjustments with a mathematical field-based system. By using continuous mathematical surfaces and plane intersections to define tool paths, the system eliminates the need for discrete mechanical reorientations, thereby reducing tool wear and maintenance while improving geometric accuracy through precise mathematical calculations.
3Manufacturing precision
If conventional tool orientation methods are used, then machining can be performed efficiently, but irregular tool orientations result in poor contact pattern precision on flank sections
Solution Approach 1:
The patent changes the tool orientation control parameters from conventional methods to a plane-based system where the tool axis is continuously aligned perpendicular to the local surface plane. This parameter transformation ensures precise and consistent contact patterns on flank sections by maintaining optimal tool-workpiece geometry throughout the machining process, thereby improving contact pattern precision without sacrificing machining efficiency.
Solution Approach 2:
The patent implements a feedback mechanism where the tool orientation is continuously determined by the local surface geometry through plane normal vectors. This feedback loop ensures that the tool maintains the optimal orientation relative to the workpiece surface at each position, resulting in precise contact patterns on flank sections while maintaining efficient material removal through automated, geometry-driven orientation control.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Method and apparatus for generating control data for controlling a tool on a machine tool comprising at least 5 axes for producing a predetermined finished part with a base body and at least one flank section projecting from the base body by machining, wherein finished part geometry data of the predetermined finished part geometry of the finished part are generated based on basic geometric parameters and path data are generated based on the finished part geometry data, wherein the path data specify which tool path along the surface of the flank section is to be followed by the tool with which tool orientation relative to the workpiece for removing material from the workpiece, wherein the tool orientation of the tool corresponds to an orientation of a rotation axis of the tool and the tool rotates about the rotation axis of the tool for removing material from the workpiece.wherein the finished part geometry data comprise position data of a group of points on the surface, wherein the position data specify a position of the points of the group of points, wherein each point of the group of points is associated with a column of points and a row of points, wherein all points of a column of points lie in a common plane and the common plane of the points of a column of points is substantially perpendicular to the base body, wherein the path data are generated such that the tool path is substantially parallel to a curve passing through the points of a first row of points, and wherein the path data are further generated such that the axis of rotation of the tool at each of the points of the first row of points is oriented substantially in the common plane of the column of the respective point of the first row.