The concept of swept sections for flat-ended tools is revisited with the goal of improving the accuracy of calculations in five-axis tool path generation. Firstly, the notions of partial and total swept sections (distinct from traditional swept sections) are introduced. It is shown that partial and total swept sections provide a more accurate representation of the geometry of the moving tool compared to traditional swept sections. Next, geometric and numerical methods focused on calculating partial swept sections are presented. These methods are based on calculating plane-circle intersections. Finally, the calculated partial swept sections are compared to the traditional swept sections. Variations from the traditional swept sections are characterized to provide guidelines to the tool path programmer. [S1087-1357(00)71101-4]

Issue Section:
Technical Papers
Keywords:
machining, tools, numerical control, manufacturing processes
Topics:
Errors, Geometry, Machining, Manufacturing, Numerical analysis, Cylinders, Machine tools
1.
Fallbohmer
,
P.
,
Altan
,
T.
,
Tonshoff
,
H. K.
, and
Nakagawa
,
T.
,
1996
, “
Survey of the Die and Mold Manufacturing Industry
,”
J. Mater. Process. Technol.
,
59
, No.
1–2
, pp.
158
–
168
.
2.
Altan
,
T.
,
Lilly
,
B. W.
,
Kruth
,
J. P.
,
Konig
,
W.
,
Tonshoff
,
H. K.
,
vanLuttervelt
,
C. A.
, and
Khairy
,
A. B.
,
1993
, “
Advanced Techniques for Die and Mold Manufacturing
,”
Annals of the CIRP
,
42
, No.
2
, pp.
707
–
716
.
3.
Whitney
,
D. E.
, and
Tung
,
E. D.
,
1992
, “
Robot Grinding and Finishing of Cast Iron Stamping Dies
,”
ASME J. Eng. Ind.
,
114
, pp.
132
–
114
.
4.
Hock
,
L.
, and
Jajenski
,
J.
,
1996
, “
NC Programming for High Speed Machining
,”
Mod. Mach. Shop.
, November, pp.
88
–
94
.
5.
Vickers
,
G. W.
, and
Quan
,
K. W.
,
1989
, “
Ball-Mills Versus End-Mills for Curved Surface Machining
,”
ASME J. Eng. Ind.
,
111
, pp.
11
–
26
.
6.
Jensen, C. G., and Anderson, D. C., 1992, “Accurate Tool Placement and Orientation for Finish Surface Machining,” Proceedings of the 1992 ASME Winter Annual Meeting, PED-Vol. 59, pp. 127–145.
7.
Lee
,
Y. S.
, and
Chang
,
T.
,
1996
, “
Automatic Cutter Selection for 5-Axis Sculptured Surface Machining
,”
Int. J. Prod. Res.
,
34
, No.
4
, pp.
977
–
998
.
8.
Marciniak, K., 1991, Geometric Modeling for Numerically Controlled Machining, Oxford University Press, Oxford.
9.
Choi
,
B. K.
,
Park
,
J. W.
, and
Jun
,
C. S.
,
1993
, “
Cutter-Location Data Optimization in 5-Axis Surface Machining
,”
Comput. Aided Des.
,
25
, No.
6
, pp.
377
–
386
.
10.
Struik, D. J., 1950, Lectures on Classical Differential Geometry, Dover, New York City.
11.
Stoyanov
,
T. E.
,
1992
, “
Marching Along Surface/Surface Intersection Curves With Adaptive Step Length
,”
Comput. Aided Geometric Des.
,
9
, pp.
485
–
489
.
12.
Sarma
,
R.
, and
Dutta
,
D.
,
1997
, “
The Geometry and Generation of NC Tool Paths
,”
ASME J. Mech. Des.
,
119
, No.
2
, pp.
253
–
258
.
13.
Lee
,
Y. S.
,
1997
, “
Admissible Tool Orientation Control of Gouging Avoidance 5-Axis Complex Surface Machining
,”
Comput. Aided Des.
,
29
, No.
7
, pp.
507
–
521
.
14.
Mullins, S. H., Jensen, C. G., and Anderson, D. C., 1993, “Scallop Elimination Based on Precise 5-Axis Tool Placement, Orientation, and Step-Over Calculations,” Proceedings of the 1993 ASME Design Automation Conference, DE-Vol. 65, pp. 535–544.
15.
Sarma, R., 1998, “Rear Gouging Detection and Elimination in Five-Axis NC Maching of Sculptured Surfaces,” Trans. NAMRI/SME, pp. 225–230.
Copyright © 2000
 by ASME
You do not currently have access to this content.