Preparation Milling Tool Path Determination for Constant Engagement Angle
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In milling processes, controlling the angle of engagement of tools to ensure efficient production time, quality, and tool longevity is challenging due to varying cutting forces caused by complex part shapes, especially when transitioning from preparation to finishing stages with different tool diameters.
Innovation Solution
A method and system for determining the path of a preparation milling tool that divides the final part profile into portions to maintain a constant angle of engagement for the finishing tool, using computational models and software modules to optimize the preparation step and adjust the path of the preparation milling tool to accommodate the constraints of both tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a preparation milling step is performed before finishing to remove large quantities of material, then productivity is improved by reducing total machining time, but the angle of engagement control becomes more difficult due to varying cutting forces during tool path
Solution Approach 1:
The method segments the machining process into distinct preparation and finishing stages, each with optimized tool paths. The preparation tool path is specifically designed to create a workpiece geometry that enables the finishing tool to maintain optimal engagement angles, thereby resolving the contradiction between high productivity and ease of operation.
Solution Approach 2:
The preparation milling step performs preliminary action by removing bulk material and shaping the workpiece in advance. This preliminary shaping ensures that when the finishing tool operates, it encounters favorable geometric conditions that facilitate constant angle of engagement, thus improving both productivity and operational ease.
2Manufacturing precision
If different diameter tools are used for preparation and finishing stages, then manufacturing precision is improved by optimizing each stage for its specific requirements, but device complexity increases due to tool path coordination
Solution Approach 1:
The method applies local quality by designing different tool paths tailored to the specific requirements of each machining stage. The preparation tool path focuses on efficient material removal, while the finishing tool path is optimized for precision and constant engagement angle, allowing each tool to perform its specific function at optimal quality levels.
Solution Approach 2:
The preparation-machined workpiece geometry acts as an intermediary between the preparation tool and finishing tool. This intermediate geometry is specifically designed to enable the finishing tool to maintain optimal engagement angles, thereby simplifying the coordination complexity while maintaining high manufacturing precision.
3Reliability
If the angle of engagement is strictly controlled to remain below maximum value, then tool life is extended and part quality is improved, but productivity decreases due to longer machining paths
Solution Approach 1:
The method introduces dynamics by adapting the tool path geometry to maintain optimal engagement angles throughout the finishing operation. Rather than using a fixed tool path, the preparation stage creates a workpiece geometry that dynamically ensures favorable engagement conditions during finishing, thereby extending tool life without significantly increasing production time.
Data Source
Figure 1~2
Figure 3A~3C
Figure 4A~4B
AI summary
The invention relates to a method for determining the path of a preparation milling tool (S) used for preparing a workpiece. The method comprises the following steps: - Determining a first path (Ts0) of the preparation milling tool (S) to create a first prepared profile (Pb) of the workpiece; - Determining at least one first non-machinable zone (Z1) of said first prepared profile (Pb) by the preparation milling tool (S) following said first path (Ts0), determined taking into account the radius (Rs) of the preparation milling tool (S); - Determining a second path (Ts1) of the preparation milling tool (S) to create a second prepared profile (Ps) of the workpiece, taking into account the radius (Rs) of said preparation milling tool (S), said at least one first prepared profile (Pb) of the workpiece, and a final profile (Pp) of the workpiece obtained after finishing.