5-Axis Flank Milling on Pseudo-Ruled Non-Ruled Surfaces
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Solution Overview
Problem
Existing CAM methods are limited in their ability to efficiently machine non-ruled surfaces using 5-axis flank milling, as they require the target surface to be ruled, which is not always the case, especially for aerodynamic profiles.
Innovation Solution
The method involves selecting a workpiece with unruled surfaces, determining sub-areas with pseudo-ruledness properties based on Gaussian curvature evaluation, and aligning a 5-axis barrel-shaped cutting tool with these sub-areas to create a tool path that follows near-zero curvature isolines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional flank milling methods are used, then high finishing quality and fast material removal rates are achieved, but only for ruled surfaces
Solution Approach 1:
The non-ruled surface is divided into multiple sub-areas, each with its own pseudo-ruledness properties and curvature characteristics. The tool path is segmented to process each sub-area independently with optimized parameters, allowing the method to handle complex non-ruled surfaces while maintaining high finishing quality.
Solution Approach 2:
The method dynamically adapts the tool orientation and path planning based on the local curvature properties of the surface at each point. By calculating and responding to varying Gaussian curvature and normal curvature values, the system optimizes tool alignment for each specific location on the non-ruled surface.
2Productivity
If 5-axis alignment with rulings is used, then efficient material removal is achieved, but only when surfaces are ruled
Solution Approach 1:
The method changes the fundamental parameter from requiring exact ruled surfaces to working with pseudo-ruled surfaces characterized by near-zero normal curvature. This parameter change allows aerodynamic profiles and other non-ruled surfaces to be processed with efficient 5-axis flank milling by adapting to their local curvature properties rather than requiring them to conform to ruled surface geometry.
3Manufacturing precision
If tight tool-target surface contact is required, then high precision is achieved, but mathematical rigor is difficult to maintain for non-ruled surfaces
Solution Approach 1:
The method performs preliminary calculations of Gaussian curvature and identification of near-zero normal curvature directions before generating the tool path. This advance preparation of geometric information simplifies the subsequent path planning process by providing pre-computed alignment directions that ensure precise tool-target contact without requiring complex real-time calculations.
Data Source
AI summary
Methods, systems, and devices for flank milling by a computer numerical control (CNC) machine by selecting a workpiece to be machined, determining a tool path for the flank milling cutting tool based on a selected flank milling cutting tool having a tool curvature matching the curvature of an identified subset of curves, where the identified subset of curves may have near-zero curvature and determined to have a direction minimizing an absolute value of a normal curvature, and where the subset of curves may be on an unruled surface and having pseudo-ruledness properties.