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Dissertations / Theses on the topic 'Five axis milling'
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1
Ferry, William Benjamin Stewart. "Virtual five-axis flank milling of jet engine impellers." Thesis, University of British Columbia, 2008. http://hdl.handle.net/2429/993.
Full textAbstract:
This thesis presents models and algorithms necessary to simulate the five-axis flank milling of jet-engine impellers in a virtual environment. The impellers are used in the compression stage of the engine and are costly, difficult to machine, and time-consuming to manufacture. To improve the productivity of the flank milling operations, a procedure to predict and optimize the cutting process is proposed. The contributions of the thesis include a novel cutter-workpiece engagement calculation algorithm, a five-axis flank milling cutting mechanics model, two methods of optimizing feed rates for impeller machining tool paths and a new five-axis chatter stability algorithm.
A semi-discrete, solid-modeling-based method of obtaining cutter-workpiece engagement (CWE) maps for five-axis flank milling with tapered ball-end mills is developed. It is compared against a benchmark z-buffer CWE calculation method, and is found to generate more accurate maps.
A cutting force prediction model for five-axis flank milling is developed. This model is able to incorporate five-axis motion, serrated, variable-pitch, tapered, helical ball-end mills and irregular cutter-workpiece engagement maps. Simulated cutting forces are compared against experimental data collected with a rotating dynamometer. Predicted X and Y forces and cutting torque are found to have a reasonable agreement with the measured values.
Two offline methods of optimizing the linear and angular feeds for the five-axis flank milling of impellers are developed. Both offer a systematic means of finding the highest feed possible, while respecting multiple constraints on the process outputs. In the thesis, application of these algorithms is shown to reduce the machining time for an impeller roughing tool path.
Finally, a chatter stability algorithm is introduced that can be used to predict the stability of five-axis flank milling operations with general cutter geometry and irregular cutter-workpiece engagement maps. Currently, the new algorithm gives chatter stability predictions suitable for high speed five-axis flank milling. However, for low-speed impeller machining, these predictions are not accurate, due to the process damping that occurs in the physical system. At the time, this effect is difficult to model and is beyond the scope of the thesis.
2
Thompson, Michael B. "Development of a five-axis machining algorithm in flat end mill roughing /." Diss., CLICK HERE for online access, 2005. http://contentdm.lib.byu.edu/ETD/image/etd823.pdf.
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3
Hendriko, ? "Advanced virtual simulation for optimal cutting parameters control in five axis milling." Thesis, Clermont-Ferrand 2, 2014. http://www.theses.fr/2014CLF22464/document.
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La thèse concerne l’usinage à 5 axes de formes complexes. Le but est d’estimer le plus précisément possible les efforts induits par la coupe pour ajuster la vitesse d’avance et gagner en performance. Pour cela, il est nécessaire d’estimer les engagements radial et axial de la fraise à chaque instant. Ce calcul est rendu particulièrement complexe à cause de la forme de la pièce, de la forme du brut et de la complexité de la géométrie de l’outil. Les méthodes usuelles par Zbuffer sont particulièrement couteuses en temps de calcul. Dans ces travaux nous proposons une méthode de calcul rapide à partir d’une modélisation du contact dans toutes les situations envisageables. Différentes simulations et expérimentations ont permis de valider la précision expérimentalementThis study presents a simple method to define the Cutter Workpiece Engagement (CWE) during sculptured surface machining in five-axis milling. The instantaneous CWE was defined by determining two engagement points, lowermost engagement (LE)-point and uppermost engagement (UE)-point. LE-point was calculated using a method called grazing method. Meanwhile the UE-point was calculated using a combination of discretization and analytical method. During rough milling and semi-finish milling, the workpiece surface was represented by vertical vector. The method called Toroidal–boundary was employed to obtain the UE-point when it was located on cutting tool at toroidal side. On the other hand, the method called Cylindrical-boundary was used to calculate the UE-point for flat-end cutter and cylindrical side of toroidal cutter. For a free-form workpiece surface, a hybrid method, which is a combination of analytical method and discrete method, was used. All the CWE models proposed in this study were verified and the results proved that the proposed method were accurate. The efficiency of the proposed model in generating CWE was also compared with Z-mapping method. The result confirmed that the proposed model was more efficient in term of computational time. The CWE model was also applied for supporting the method to predict cutting forces. The test results showed that the predicted cutting force has a good agreement with the cutting force generated from the experimental work
4
Cengiz, Ender. "Development Of Postprocessor, Simulation And Verification Software For A Five-axis Cnc Milling Machine." Master's thesis, METU, 2005. http://etd.lib.metu.edu.tr/upload/2/12606565/index.pdf.
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Five-axis CNC milling machine tools bring great facility to produce complex workpieces with increased dimensional accuracy and better surface quality in shorter machining times. However, kinematics of five-axis machine tools has a complex form which makes it difficult to operate these machine tools properly. The difficulty arises from the complexity of NC-Code generation and tool path verification. Collision of machine tool or setup components with each other is a severe problem in five-axis machining operations and usually results from inadequate postprocessors or insufficient collision checking due to absence of well-prepared simulation and verification programs. Five-axis CNC machine tool owners may get rid of this problem by purchasing commercial postprocessors, simulation and verification programs. However, these programs are expensive and small and medium enterprises (SME&rsquos) usually cannot afford the costs of these programs. In the related libraries of commercial programs, there is great number of CNC machine tools, which is generally unnecessary for SME&rsquo
s. An alternative to overcome this problem is to develop particular program, which is capable of postprocessing, simulating and verifying milling operations, for each certain five-axis CNC machine tool. In this study, a software named &ldquo
Manus 1.0&rdquo
, which performs postprocessing and simulation processes, has been developed for the high speed &ldquo
Mazak Variaxis 630-5X&rdquo
CNC five-axis machine tool, located in METU-BILTIR Center. Moreover, tool path verification algorithms have been developed to detect collisions. The software has been written in Borland C++ Builder5.0. The developed program has been tested in sample milling operations and satisfactory results have been achieved.
5
Werkmeister, Jaime Brooke 1977. "Design and fabrication of the MesoMill : a five-axis milling machine for meso-scaled parts." Thesis, Massachusetts Institute of Technology, 2004. http://hdl.handle.net/1721.1/27142.
Full textAbstract:
Thesis (S.M.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 2004.Includes bibliographical references (p. 113-115).
With the increased prevalence of meso-scaled products, new tools are being developed to bridge the gap between fabrication processes tailored for micrometer and millimeter sized features. Compared to its traditional counterpart, a small machine tool designed for meso-scale could potentially have a smaller overall footprint, shorter structural loop and lower cost than a conventional machine; in addition, a small machine presents opportunities for improved machine metrology, and easier environmental control. This paper describes the design of the MesoMill: a test machine designed to evaluate the use of components new to the design of machining centers including wire capstan drives, ball-screw splines, and an air bearing spindle with an integral Z-axis.
by Jaime Brooke Werkmeister.
S.M.
6
Tuysuz, Oguzhan. "Prediction of cutting forces in three- and five-axis ball-end milling with tool indentation effect." Thesis, University of British Columbia, 2012. http://hdl.handle.net/2429/40071.
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In machining, the desired final shape is created in Computer Aided Design (CAD) environment and this information is forwarded to Computer Aided Manufacturing (CAM) phase in which the toolpath is generated and converted to machine specific commands for part manufacturing. The steps in CAD/CAM environments are geometry dependent only, and do not include the physics of the process. However, mathematical modeling of the machining operation gives the flexibility of identifying and resolving process related issues i.e. tool breakage, chatter vibrations and tolerance violations beforehand, which in turn leads to increased productivity.
The first step of process modeling is to model the mechanics of the operation that leads to the prediction of the cutting forces experienced by the cutting tool and the workpiece. In this study the mechanics of ball-end tool which is commonly used to machine parts with free-form geometric features are studied. The main problem in ball-end milling mechanics is tool indentation which leads to inaccurate force prediction in tool axial direction, and has previously been solved experimentally only for specific cases. This thesis presents a generalized ball-end tool indentation detection and indentation force prediction model for any kind of work material and cutting tool geometry combinations. The static ball-end milling forces with indentation forces are predicted by developing an analytical cutting edge indentation model. The proposed model utilizes indentation mechanics of punch and wedge shape indenters, describes the required conditions for indentation occurrence and evaluates plastic and elastic contact pressures at the cutting edge and workpiece interface using the material properties of the workpiece.
Cutting edge indentation mechanism is also studied through finite element (FE) modeling. A general FE model is obtained for the problem and results are reported only for the material cut in the thesis.
The model proposed in the thesis has been verified experimentally. After integrating the developed indentation force prediction model into the cutting force model, predictions in tool axial direction are improved by 15-40% depending on type of the operation. The contribution of the thesis can be used in cutting force based ball-end milling process optimization and analysis for industrial applications.
7
Skácel, Jan. "Využití parametrického programování pro obrábění obecných ploch." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2015. http://www.nusl.cz/ntk/nusl-232184.
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8
Pekárek, Mojmír. "C osa pro výměnné hlavy u frézovacích obráběcích center s vodorovnou osou vřetena center smykadlového typu." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2020. http://www.nusl.cz/ntk/nusl-417760.
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This thesis deals with designing of C axis for interchangeable heads for milling machining centres with horizontal spindle centre of the slide type. It’s divided into three parts, whereas the first part contains theoretical introduction to the problematic. The second part deals with systematic analysis of the topic and choosing the right variant for elaboration. The last part forms construction design of the chosen variant, which contains notes on the solution proce-dure, calculations and visualization in form of 3D models.
9
Dvořáček, Jan. "Analýza silového zatížení řezného nástroje při pětiosém frézování." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2009. http://www.nusl.cz/ntk/nusl-228829.
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The diploma thesis is focused on machining using the ball-end shank mill. Content of the preliminary part of the work is a shank mill characteristic and a consequent part shows a splitting of ball-end milling cutters, its application, the cutting tool geometry and a characteristic signs of machining. The cutting force model of the ball-end mill is presented as well. A part of proposed model is the conversion of the resultant force too. Practical part is aimed at cutting force analysis of the ball-end mill and the main purpose of this part is a quantification of the cutting force for different work piece tilt angles while milling is performed.
10
Liang, Hung-Pin, and 梁宏彬. "Multi-axis Milling of Spherical Surfaces by Five-axis Machining Center." Thesis, 2007. http://ndltd.ncl.edu.tw/handle/4hmzx6.
Full textAbstract:
碩士國立臺北科技大學
製造科技研究所
95
Recently, many product designers of various industries, such as automobile, semiconductor, electronic parts, and mold industries tend to design products featured with complex surface. Request for the efficiency, accuracy and machining of these complex surface, it is the important way to achieve competition advantage by developing high efficiency, accuracy, and quality five-axis machining techniques. This paper attempts to develop key technology used in die machining with spherical surface by application of the CAD/CAM software and 5-axis machining center. The goal of the study is to find the optimal machining parameters for better surface finish, and thus significantly reduce time, cost, and error in further bench working. In this study, a commercial CAD/CAM Software is used to plan and generate the multi-axis tool path, and a table rotating/tilting type five-axis machining center is used to perform the experimental machining operation. The material of the die studied is NAK 80 die tool steel, and the geometries are modeled as concave and convex spherical surfaces. Milling parameters considered are spindle speed, feed rate, and different types of cutting tool path. The experimental results show that the surface roughness for concave spherical surface is about 0.247 μm and roundness is about 0.0283 mm and the surface roughness for convex spherical surface is about 0.250 μm and spherical roundness is about 0.0551 mm under the cutting conditions mentioned in this study. It is believed that the results and methods presented in the thesis give a good reference for industry.
11
Perng, Chau Tzong, and 彭朝宗. "feedforward control appllied on a five-axis milling machine." Thesis, 1995. http://ndltd.ncl.edu.tw/handle/19459412451331416377.
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碩士國立清華大學
動力機械學系
83
Conventionally cutting a free-form surface workpiece needs a 3-axis milling machine, but too much time is spent, thus 5- axis milling machines are used to reduce the time needed in the machining process. This thesis is dedicated to investigate the contouring errors in CNC maching process, by the way the tran- sformation equations needed for 5-axis CNC is also derived. Besides, this thesis applies feedforward control to improve the contouring performance. Feedforward control uses the system imformation obtained by identification process to distort the setting value so that the actual value will the same as the setting value. Because most of the paths produced in 5 axis CNC machining are curves, following errors will produce contouring errors,through our experiments of going circle paths, following error is reduced to 1/30 to 1/50 of the original, and contouring error is reduced to 2/3 to 1/2 of the original.
12
Huang, Chi-Hui, and 黃繼輝. "Optimization of Five-axis CNC Milling Operations using Taguchi Methods." Thesis, 2008. http://ndltd.ncl.edu.tw/handle/jw2mm8.
Full textAbstract:
碩士國立臺北科技大學
製造科技研究所
96
Different kinds of complex surfaces of products have become popular in product design in recent years and consequently 5-axis machining techniques become a mainstream in the manufacturing of the die and moulds used in products mentioned above, because of their features and flexibility. This research applies Taguchi method to find out a set of optimal machining parameters in five-axis milling process. The table rotating-tilting type five-axis machine is used to perform the experimental cutting in this study. The geometry of die is modeled as convex half spherical surface, and the material of die is NAK 80 die steel. Experimental procedures consist of using L9(34)orthogonal array, calculating S/N ratio, charting broken-line graph, and response plane, optimizing parameters, an applying ANOVA analysis chart to verify Taguchi experiment results. The four parameters studied are cutting speed, feed rate, tool paths, and contact points, and each of these factors has three levels. The target of this study is the feature of smaller-the-better that is minimization of the surface roughness. The final results of optimal surface roughness experiment shows that the optimal parameters are 12,000rpm cutting speed, 600mm/min feed rate, five-axis tool path, and 360 contact points. The results of ANOVA analysis is correspondent with our research and that can prove Taguchi method is effective. The factors contributing most to the improvement of surface roughness is tool path which accounts for 60.5%,the second is spindle speed. Besides surface roughness, we also conduct research for roundness using the same experiment procedures applied for surface roughness because they have the same quality character. The optimal machining parameters for roundness is 10,000rpm cutting speed, 900mm/min feed rate, five-axis tool path, and 360 contact points. The results of ANOVA analysis is correspondent with our research and that can prove Taguchi method is effective. The factors contributing most to the improvement of surface roughness is tool path which accounts for 25%, the second is tooling contact point.
13
Yu, Jhih-Long, and 余誌隆. "Study of an Interactive 3D Five-axis Milling Machining Simulation System." Thesis, 2013. http://ndltd.ncl.edu.tw/handle/01277731397054968844.
Full textAbstract:
碩士國立高雄應用科技大學
機械與精密工程研究所
101
For the inclined plane workpiece, five-axis machining is no need to exchange the fixtures frequently, avoiding the positioning errors and wasting time by setting the origin of coordinates again, and also can complete all working procedure at one time, therefore five-axis machining can manufacture the finished product with high efficiency. Postprocessor is an important interface for designing and manufacturing the five-axis NC code. Due to the different five-axis NC code is suitable to different machining, postprocessor is used to transform the five-axis NC code into different machining’s NC code. This research has developed a set of five-axis milling simulation system; users can define the machine components by themselves. The developed modularity ability can be used for setting the machine tool model and the developed postprocessor has been used to generate NC code successfully. Several virtual controller and operation panels have also been developed to emulate the real five-axis machine tool operation. The developed system can interpret five-axis NC program and drive the interactive 3D five-axis machine tool for cutting simulation and for operation education and training. This research has been successfully integrated with a table-tilting five-axis machine tool STC-450 of “Shang Nong Industry Co. Ltd.”. A special 3D HMI has also been developed to generate five-axis NC program for an automotive component five-axis machining processes.
14
Chyuarn, Sue Yuh, and 蘇育全. "Tool-path Planning for Five-axis Milling of Free-form Surface." Thesis, 1995. http://ndltd.ncl.edu.tw/handle/28043627336202910971.
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15
Lin, Zhong-Cheng, and 林忠誠. "Cutting Forces Analysis for Five-Axis Flank Milling of Ruled Surface." Thesis, 2007. http://ndltd.ncl.edu.tw/handle/639ntb.
Full textAbstract:
碩士國立臺北科技大學
製造科技研究所
95
The end mill cutter is one of the most important cutters of milling machines, and the magnitude of cutting forces and varies of forces position are main keys that influence dimensional precision and surface roughness of the machined surface. Today, where everyone requests high machining quality and efficiency for the planning of the cutting process, it is very important for us to probe into the research of cutting forces of the end mill cutter. Five-axis machines include not only three linear axes but also two rotation axes that can to drive simultaneously the end mill cutter performing flank milling for the ruled surface. It is convenient and widely used. However, there are few reports containing the analysis of the cutting forces for flank milling, even rarer about the analysis of cutting forces for flank milling indevelopable ruled surface. This paper aims to show the analysis of cutting forces when flank milling ruled surface with end mill cutter for five-axis machining. First of all, the specific cutting force parameters are obtained by using three-axis end milling experiments. Second, use the five-axis flank milling tool path data to calculate the variation of feedrate along the axis direction of the end mill in order to compute the instantaneous tool cutting forces. Therefore, we can predict the variation of the cutting forces during the end mill moving along the ruled surface. The approach of this paper is suitable for carrying out prediction of cutting forces for flank milling ruled surface under reserving uniform material to cut by using five-axis machine. And it can effectively provide the suggestions of process planning for five-axis flank milling operation.
16
Tsai, Wei-Lun, and 蔡瑋倫. "GPGPU-Based Optimization of Tool Path Planning for Five-Axis Flank Milling." Thesis, 2008. http://ndltd.ncl.edu.tw/handle/29022984359919434878.
Full textAbstract:
碩士國立清華大學
工業工程與工程管理學系
96
Ruled surfaces provide a good capability of complex product modeling. Such geometry has been widely used in the aero-space, automobile, and mold industries. For example, turbine blade is a key component in energy and air-conditioning applications. The shape design involves advanced fluid mechanics. The manufacturing task is generally performed by companies specialized in five-axis CNC machining. It requires computer-aided manufacturing (CAM) technology and cutting experiences. The development of turbine blade is considered an indicator of industrial competence. In current practice, the cutter goes along the rulings of a ruled surface, thus finishing the machining job. However, this machining method does not produce optimal machining quality. Thus, several studies had attempted to improve it. Most of the adopt local optimization approaches or heuristic algorithms, which do not guarantee globally best result. Their computational efficiency is poor. As a result, the tool path planning of five-axis flank milling is highly limited. The machining quality cannot be precisely controlled. To overcome this deficiency, this research proposes a novel computational scheme that estimates the machining error using general-purpose graphic processing unit (GPGPU) in five-axis flank milling. GPGPU provides excellent functionality of parallel processing. The processing speed of floating number is faster than CPU. This computing technology has been applied to many engineering problems in addition to computer graphics. This research is one pioneering work that applies GPGPU in five-axis tool path planning. It cooperates physical limitations into the path planning such as feed, rotation angles, and cutting length. Quadrilateral patches are used for generation of optimal tool path in terms of minimal machining error. We convert a geometric problem into a math programming task. First, a network is constructed for modeling feasible solution of tool motions. The machining errors induced by individual tool motions become the weights between the nodes of the network. It thus transforms into a shortest path problem and can be easily solved by the Dijkstra’s algorithm. For complex machining conditions, we employ GA (Genetic Algorithm) for searching optimal tool path empowered by the parallel processing provided by GPGPU. The resultant GA algorithm can perform cross-over and mutation operations rapidly. It also considers linear interpolation between tool motions. Efficient encoding/decoding schemes are developed to fulfill the actual requirements of 5-axis machining. Simulation result produced by commercial software is obtained for verification purpose. Finally, a real cutting experiment is conducted to validate the effectiveness of the proposed scheme. CMM measure of the machining part shows that it significantly improves the machining quality of 5-axis flank milling. This work provides advantages on computational efficiency, machined quality, and planning flexibility for 5-axis flank milling of complex ruled geometry.
17
CAI, ZONG-YAN, and 蔡宗諺. "Process Study for Fabricating Polylactic Acid Medical Stents with Five Axis Milling." Thesis, 2018. http://ndltd.ncl.edu.tw/handle/qgvm89.
Full textAbstract:
碩士國立臺灣科技大學
機械工程系
106
Biliary stent is a medical device with a hollow tubular structure. The main purpose is to support gallbladder duct wall in order that bile can pass through the blocked bile duct smoothly. The common material used for the degradable stents is polylactic acid (PLA). The PLA stent will be completely absorbed by the body; therefore, it is unnecessary to operate the secondary surgery to remove the stent. Also, there will be less problem of re-clogging. The stent can be implanted in human body with sufficient mechanical strength and biocompatibility. Nowadays, most of the bile duct stents are manufactured by laser processing, which makes the acute angle structure present on the side wall of the stent. It may cause unpredictable injury to the vessels due to a sharp angle of the stent in medical treatment. In this study, the manufacture of degradable stents was performed by means of micro-milling. Miniature ball-shaped cutters are used to process PLA stents and to improve the problem of sharp edges. This research was conducted the biodegradable stents that were milled by using a five-axis machine. The main process is to use an additive manufacturing method to produce a base material, in order to improve the precision of the additive manufacturing , external milling is performed before machining to ensure the outer diameter. Because the PLA material is less than the metal strength, it is easy to bend during processing.In order to avoid this phenomenon ,The depth of the layered processing is used to reduce the pressure on the billet during processing to reduce the amount of bending.Improve the actual depth of cut. And it has been verified that the acute angle of the stent struts can be removed by micro-milling. This study successfully produced biodegradable, which is 10mm in diameter, 0.6 mm in thickness, and 0.15R in radius, through experiments.
18
Liao, Kai-Wei, and 廖凱偉. "Five-axis Tool Path Planning for Rough Milling and Finish Milling Hub Surface of the Centrifugal Impeller." Thesis, 2007. http://ndltd.ncl.edu.tw/handle/x926hm.
Full textAbstract:
碩士國立臺北科技大學
製造科技研究所
95
This paper proposed a new tool path planning method for rough milling and finish milling the hub surface of the centrifugal impeller. We use MATLAB to calculate rough milling and finish milling tool path location data including tool-axis orientation. All the calculated tool location data then input Unigraphics CAD/CAM (UG) Software to simulate and confirm that the rough milling and finish milling operations are correct. And then using UG postprocessor to transform tool location data into NC-code for five-axis machining （machine type HA-5AX3, five axes are X, Y, Z, B, and C）. The tool path planning of rough machining is meant for removing the material between two blades of the hub of impeller excluding finish milling allowance of the blade surfaces and finish milling allowance of the hub surface. This paper also plan finish milling path of the hub surface. Based on the parametric equations of blade surfaces and hub surface, and selected form specification of the ball end mill, we use MATLAB to calculate the coordinates of tool paths and tool-axis orientation. Rough milling and finish milling operations are all adopted Zig-Zag tool path pattern. Rough machining is divided evenly into four layers, and their main cutting directions are perpendicular to flow direction of the blade. The direction of finish milling path of hub surface obeys blade flow direction, and it can remain the final finishing mark direction are indentical with airflow. This paper constructed a five-axis tool path planning method can precisely mill the hub surface of centrifugal impeller.
19
En-PingHsieh and 謝恩平. "An Octree Method for Milling Force Prediction in Five-Axis Virtual Machine Tool." Thesis, 2013. http://ndltd.ncl.edu.tw/handle/47690928739410103283.
Full textAbstract:
碩士國立成功大學
機械工程學系碩博士班
101
Generally, products for aerospace or mold industries need superior precision. Since the manufacturing processes are difficult and time-consuming in traditional 3-axis machine tool. To improve the accuracy and productivity of the products, the five-axis machine tools are introduced to the manufacturing industries. In five-axis machining, engineers set the operation parameter more cautious to decrease the possibility of tool breakage caused by peak force, which is ineffective and time-consuming. To solve the aforementioned problems, a system to simulate the milling process and to predict milling force is proposed. The contribution of the thesis includes an algorithm connecting between geometric simulation and instantaneous static milling force model in five-axis machining process and a system to monitor the milling force in the five-axis virtual machine tool. An algorithm combining octree method of geometry simulation with general milling cutter and five-axis semi-discrete milling force model is developed. It presents the cutter-workpiece engagement geometry along tool paths and predicts the milling force at the same time. Moreover, a five-axis virtual machine tool simulation system is developed. It provides basic functions of commercial controllers and presents five-axis motion animation. Furthermore, it presents the comparison with the tool paths via virtual controller and commercial controller. Finally, the algorithm of milling force prediction is verified by previous literature, and it proved that the result of this thesis is reasonable; and the virtual five-axis machine tool system simulates the entire operation appropriately. As a consequence, the prediction of milling force in five-axis virtual machine tool system is reliable and valuable.
20
Do, Xuan-Hoa, and 杜順和. "Case Study on Virtual Five-Axis CNC Milling Machine Modeling and Motion Simulation." Thesis, 2011. http://ndltd.ncl.edu.tw/handle/86823852598610724819.
Full textAbstract:
碩士國立高雄應用科技大學
精密模具與機械產研碩士外國專班
99
The virtual reality (VR) technology has been researched and developed dramatically in recent years. Its importance and application, in engineering and education, have been discussed and displayed in various science conferences. In engineering, many works have been proposed relating to VR technology at universities and research institutes around the world. Despite of what scientists have achieved, VR technology is still a broad and worth topic to research and discover at the moment and in the future. Along with development of VR technology in engineering, this thesis proposes a new method in modeling and simulation of virtual machine tools. Three kinds of five-axis CNC milling machine tools are taken as research objects: Head – Table machine, Head – Head machine and Table – Table machine. The machine configurations are constructed basing on a LNC-M520HC five-axis machining center in the Remote Virtual Rapid Manufacturing Laboratory, Department of Mechanical Engineering, National Kaohsiung University of Applied Sciences, Taiwan. The method mainly uses CATIA software to build, define and simulate these three machines. The kinematic relationship between the components, home position, travel limits, etc of the machines are defined. The virtual machine tools then are simulated with three certain manufacturing processes. During the simulation, tool-path and cutting process with work-piece deformation are dynamically displayed and edited. Besides, the collision between components of the machines could be detected and avoided. After that, VERICUT software is employed to model these three types of five – axis machine. For Head – Table machine, one machining program is used to test this machine. In which, this program is created by CATIA software. The simulation is conducted in both of two cases of using APT code and NC code. The NC code is created from APT code by using post – processor software. Also, an experiment is installed and run on real machine. At the end of machining process, the machined part is compared with simulation result. The significance of the proposed method is that it can be applied in engineering as well as in training and education. This issue is briefly discussed at the end of the thesis.
21
Lai, Ming-Chyn, and 賴銘勤. "A Computer Aided Milling-Cutter Manufacturing System For Five-Axis CNC Tool Grinder." Thesis, 2002. http://ndltd.ncl.edu.tw/handle/99426569690673867409.
Full textAbstract:
碩士國立交通大學
機械工程系
90
Cutting tools play a very important role in the field of mechanical manufacturing. The performance and quality of tools have direct and serious influences on the precision and efficiency of cutting machining and the quality of products. Milling operations are predominantly used for milling complex surface shapes. So we must be careful with the demand of milling cutters themselves. In the past, the traditional tool grinder was being used to grind tools limited to a few functions and needed other grinding attachments, to take the grinding separately. By doing so, it loses some precision of the milling cutters and resulting in eliminating chips unevenly in milling operations. Moreover, for common manufacturers, the technique of helical groove machining of the milling cutters is still approached from an empirical trial and error method. Owing to lack of identical and common basis of milling, this makes the milling operations standardized lately. Recently, the development of the multi-axes CNC tool grinder makes it possible to finish just one process. By this way, it is helpful to get better precision of the milling cutters and eliminate chips smoothly. However, there are still some integral problems of manufacturing system existing in the domestic tool grinding operations. What is obvious is the lack of an effective CAM system, which is necessary to design milling cutters and plan the grinding process, so as to attend the goal of flexibility and automation of the all operations. This research is trying to build the mathematical geometry model of milling cutters firstly, and then to develop the simulation software of grinding milling cutters. The functions of the software include the cross-profile evaluation mode of milling cutters after grinding. The user-friendly processes planning mode is also provided. The proposed system provides post process to generate NC code for specified five-axes CNC tool grinder. It enables us to submit NC code to the tool grinder to process machining via RS232 port or other specified I/O port. V ERICUT Simulation Software and laser displacement detector is adopted to measure the tool profile of the grinded products. If needed, compensation of some typical parameter is available. Beside of the development of integrated software system, the five-axes tool grinding machine system, NCTU_CIDM_TOOL 2002, is also constructed for evaluation and demonstration of the study.
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LO, PEI-HUA, and 羅培華. "Z-Level Contour Method Applied to Dental Crown Machining in Five-Axis Milling." Thesis, 2017. http://ndltd.ncl.edu.tw/handle/68m7ka.
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碩士國立中正大學
機械工程系研究所
105
In a dental CAD/CAM system, when milling the concave area of the inside surface of a tooth crown, the machining direction of the tool has to be adjusted constantly in order to avoid gauging or over-cutting. For some under-cut area, the tool also needs to be tilted to machine the under-cut area, otherwise the crown may not seat properly on the abutment due to interference. The purpose of this research is to establish a new 5-axis tool path generation algorithm. Based on the triangular mesh model, a hybrid C-Space and Centroid method is proposed to quickly search the proper tool axis directions. The establishment of a computer-aided manufacturing (CAM) system for automatic tool-path generation is applied to dental crown machining. The traditional 3-axis machining, when applied to complex surface milling of a dental crown, has never been satisfactory. It cannot produce the desired smooth and gauging free surface. In this thesis, we use the STL format to generate a 5-axis tool-path. First, the orientation of the workpiece will be corrected to reduce tool inclination changes. Secondly, the system generates the tool-path by the Z-Level algorithm. Finally, we use the proposed hybrid C-Space and Centripetal method to determine the tool axis. The integration of the above methods makes the automatic tool-path generation of the crown surface possible, which is very important for the automation of a dental CAD/CAM system.
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Chung-HuaWu and 吳昌樺. "Application of Cutting Geometry to Evaluation of Milling Force for Five-Axis Virtual Machining." Thesis, 2011. http://ndltd.ncl.edu.tw/handle/44446385235638915041.
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林羿帆, Yi-Fan Lin, and 林羿帆. "Optimization of Cutting Parameters for Five-Axis Milling of Complex Surfaces for NAK80 Steel." Thesis, 2011. http://ndltd.ncl.edu.tw/handle/3umt35.
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碩士國立臺北科技大學
製造科技研究所
99
Many designers of industrial products tend to design product featured with complex surface. In order to improve the surface quality and accuracy of work piece and thus reduce time, cost, and error in further bench working, we design an experiment to optimize the cutting parameters for minimizing the roughness of a complex surface machined on NAK80. The table rotating-tilting type five-axis machine is used to perform the experimental cutting in this study. Unigraphcis CAD/CAM software is used to plan the tool path for milling process. The four parameters studied are spindle speed, feed rate, tool paths, and stepover, and each of these factors has three levels. Use the Taguchi method to find the optimal machining parameters. The target of this study is the feature of lower-the-better that is minimization of the surface roughness. The final results of this study showed that the optimal parameters are 12,000 rpm spindle speed, 600 mm/min feed rate, follow periphery, and 600 stepover, and the best surface roughness produced are 0.2361μm. The results of ANOVA analysis is correspondent with this result. The factor contributed most to the surface roughness is tool path and is 82.99％.
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LI, YING-JHE, and 李英哲. "Study on the Influence of Surface Inclination on Hyperboloid Milling in Five-Axis Machining." Thesis, 2019. http://ndltd.ncl.edu.tw/handle/fb2p8w.
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碩士明新科技大學
機械工程系精密機電工程碩士在職專班
107
In modern times, computer numerical control machines (CNCs) have more important responsibilities and offer advantages in terms of quality, speed, and cost. With the advancement of processing technology, CNC machine tools have multiple machining and multi-axis functions, saving more machine space, improving machining accuracy, reliability, and shortening machining time, especially in the field of mold processing. Excellent surface precision and surface roughness. Hyperboloids occupy a fairly common and important position in product design. In this study, the hyperbolic convex surface (floating island) of the aluminum alloy (AL6061-T6) material in the five-axis machining is processed by the inclined tool angle (tilt machining), and the difference between the U-axis and the V-axis machining path is considered. And use the computer aided design (computer aided design , CAD) software Solidworks to draw 3D models, The machining program is then programmed with the (Computer Aided Manufacturing , CAM) software hyperMill.
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Chiu, Cheng-Min, and 邱政民. "SPIRAL BEVEL GEAR MANUFACTURING ON A CNC FIVE-AXIS MACHINE USING BELL-TYPE MILLING CUTTERS." Thesis, 2014. http://ndltd.ncl.edu.tw/handle/92428528197542529972.
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碩士國立臺灣科技大學
機械工程系
102
Compared with straight bevel gears, spiral bevel gears have been more widely used in industry due to their better transmission performance and lower noise. Spiral bevel gears are generally produced by cutting methods, such as face-milling and face-hobbing methods. However, the cutting methods need to use special cutting tools and implement on dedicated cutting machines. For the production of small or moderate amount of gear manufacturers that isn’t meet the cost. Considering cost and flexible manufacturing of bevel gears in small and medium batch size, five-axis machine center is another good option compared with the dedicated bevel gear cutting machine. Company Heller in cooperation with company Gleason offered a new solution for bevel gear cutting on its five-axis machine tool. Here, a bell-type milling cutter with indexable inserts replaces the special face-milling cutterhead. However, it did not disclose the details of such application due to commercial considerations. The main goal of this paper is to establish a mathematical model of spiral bevel gear using a bell-type milling cutter on a five-axis machine center. First, a mathematical model of spiral bevel gear with the Gleason SGDH cutting method is established as a standard gear, and a virtual machine is proposed to provide movements between the cutter and the work gear. The generating gear purely rolls with the work gear that will obtain the tooth surface. This model contains three modules: a cutter, an imaginary generating gear, and the relative motion between an imaginary generating gear and work gear. And then, conversion from the virtual machine enables derivation of the nonlinear coordinates of the CNC five-axis machine. Finally, flank topographic errors are evaluated by compared with the theoretical tooth surface, and the five-axis tool paths is confirmed using VERICUT NC simulation software.
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Wang, Chih Wei, and 王志偉. "Tool-path Planning for Five-axis Milling with consideration about dynamic error of cutting tools." Thesis, 1996. http://ndltd.ncl.edu.tw/handle/37602991840012485231.
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Dai, Ting-Yi, and 戴廷頤. "Analysis and Verfication of Vibration for Saddle portion of a five-axis Milling and Turning Machine Tool." Thesis, 2016. http://ndltd.ncl.edu.tw/handle/h556sf.
Full textAbstract:
碩士國立臺北科技大學
製造科技研究所
104
The research focuses on finite element analyses and vibratory response measurements for five-axis Milling and Turning Machine Tool. This study focused on the saddle portion of the five-axis machine tools to deal with frequency analysis. In the FEA,use Solidworks simulation to do the nature frequency analysis of the saddle portion. In the experiment, use the three-axis accelerometer to obtain the resonance frequency response data of the saddle portion. And then use the time-frequency analysis software, Visual Signal, to analyse the data and find out the resonance frequencies, mode of vibration. The experiment result was also compared with the finite element analytic result, so the practicability and credibility of the finite element analyses were verified. The results show that in addition to the first model error is about 14%, the other model errors are within 6%. And according to the differences are discussed and regulate. It ensures an equivalent model can be representative of the actual structure. Completed the experiments and analysis, it could find the resonance frequencies of saddle portion. In order to avoid the frequency when the machine works on. It would establish an equivalent model of five-Axis Milling and Turning Machine Tool abound with the reference value in the future.
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PengXu and 徐鵬. "Studies on Process Optimization Based on the Cutting Force Prediction Model of an Artificial Neural Network for Five-axis Milling." Thesis, 2015. http://ndltd.ncl.edu.tw/handle/55647548718398851201.
Full textAbstract:
碩士國立成功大學
機械工程學系
103
The evolution of the five-axis machining systems and Computer Numerical Control (CNC) machine tools has provided considerable advantages for high-precision manufacturing. However, due to a conservative machining strategy,parameter value shave usually been preset as constants to avoid tool damage or breakage. Unfortunately, this practice leads to a great expense of machining time. So improving production efficiency is an important issue for machining applications such as five-axis milling, especially when machining complex surface parts. With the development of virtual simulation technology, optimizing machining parameters before machining is now recognized as a feasible method to improve efficiency. Based on this consideration, this thesis proposes a novel milling process optimization method to regulate milling constraints and adjust parameters so as to maximize the five-axis milling efficiency. As cutting force is the primary constraint, the cutting-force model is first analyzed to identify the necessary force components. The employed artificial neural network (ANN) is trained with collected milling data to predict milling force. Then,a model with all constraints, including drive conditions and force,is established to compute the optimal spindle speed and feed rate in each cutting engagement interval. With the optimized results of each milling interval, a series of process optimization algorithms are proposed to evaluate and integrate the optimal parameters in the process. All these processes are carried out in a virtual machining environment. Finally, the new milling data could be used to directly modify the cutter location (CL)file. In Addition, several case examples have been provided to verify the optimization performance of this method, which was found to be effective and reliable.
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Liu, Mao-Jung, and 劉懋融. "An Investigation on the Characteristics of the Curved Surface in High Speed Milling Al6061-T6 by a Five-axis Machine Tool." Thesis, 2014. http://ndltd.ncl.edu.tw/handle/45503435773808488203.
Full textAbstract:
碩士國立屏東科技大學
機械工程系所
102
The purpose of this study is to investigate the characteristics of the curved surface in high speed milling Al6061-T6 aluminum alloy by using a five-axis machine tool. The effects on surface roughness and curvature of the machined surface for different milling conditions are studied. The requirement of polishing level surface is achieved for all milling conditions in this study. Firstly, based on high speed machining theory is considered to select fixed milling conditions with spindle speed as 12000 rpm, feed rate as 1000 mm/min, depth of cut as 0.2mm , pitch as 0.1 mm and use of cutting fluid. The variable milling conditions are 5 inclined tool-axis as 0 °, -10 °, -20 °, -30 ° and -40 °; and 3 different milling processes as down milling with unidirectional toolpath, up milling with unidirectional toolpath, and down-up milling with bidirectional toolpath ; as a result , 15 combination of tests are performed. Measurement of average surface and curvature of the machined curved surface are conducted. It was shown that a minimum surface roughness is found as Ra 0.388μm by conducting -100 inclined tool-axis combined with down milling unidirectional toolpath. Furthermore, all of 15 milling conditions can produce polishing level surface requirement as Ra 0.8~0.015μm. In addition, the designed curvature standard in this study is 0.04. A minimum error compared with this standard is found as 0.05% by conducting -100 inclined tool-axis combined with down milling with unidirectional toolpath. It can be concluded that the use of negative angle inclined tool-axis combined with down milling with directional toolpath will improve the quality of machined surface to reach polished level by a five-axis machine tool. Therefore, a subsequent processing time and cost can be reduced and productivity will be improved.
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Chang, Yu-Chih, and 張育誌. "An Investigation on the Optimum Parameters in High Speed Milling Nickel-based Alloy of Turbine Blade by a Five-axis Machine Tool." Thesis, 2018. http://ndltd.ncl.edu.tw/handle/m22zgr.
Full textAbstract:
碩士國立屏東科技大學
機械工程系所
106
In this study, we use the milling nickel-based Inconel 718 turbine blade of the five-axis machine tool to explore how the optimal combination of parameters can be obtained from the high-speed milling in the course of the curve surface respectively against the single quality characteristic of the surface roughness and the processing time. Due to the inconsistency in the optimal combination of parameters between such two quality characteristics as the surface roughness and the processing time, we further utilize the grey relational analysis as well as the fuzzy inference system to obtain their multiple quality characteristics. First of all, we make use of the Taguchi’s robust manufacturing process design to conduct the experiment by planning the parameter combination in terms of the L16(45) orthogonal arrays, measure each surface roughness posterior to the experiment and record the processing time of the experiment. Based on the experimental results, we analyze the signal to noise ratio (S/N Ratio) of each quality characteristic and separately obtain the optimal parameter combination of single quality characteristic of the surface roughness and the processing time. Next we take the Ra 0.4 μm of the surface roughness as the restrictive requirement and find out the multiple quality characteristic which simultaneously considers the surface roughness and the processing time by way of the grey relational analysis and the fuzzy inference system. As the study results indicate, when the optimal parameter combination of the multiple quality characteristic is adopted in the processing, the mean value of the surface roughness Ra we obtain is 0.3924μm, and took 325 sec, which corresponds to the restrictive conditions. Compared to the Taguchi’s robust manufacturing process experiment, in which the surface roughness Ra meets the requirement of less than 0.4μm with the 564 sec that the shortest processing time, the processing efficiency is improved by 42.3%. Via the grey relational analysis and the fuzzy inference system, this study integrates two different quality characteristics of the surface roughness and the processing time into the optimal parameter combination of one single quality characteristic. The results prove that the processing efficiency can be actually upgraded, concurrently taking the quality objective into consideration. Besides, the users can alter the restrictive conditions, depending on their needs.