Combining physical shell mapping and reverse-compensation optimisation for spiral machining of free-form surfaces. Issue 13 (3rd July 2019)

• Record Type: Journal Article
• Authors: Li, Xiongbing; Liu, Zhiping; Wang, Fulin; Yi, Bing; Song, Yongfeng
• Is Part Of: International journal of production research. Volume 57:Issue 13(2019)
• Page Start: 4118
• Page End: 4131
• Publication Date: 2019-07-03
• Subjects: physical shell mapping -- reverse-compensation optimisation -- less-distortion flattening -- C2 continuous spiral tool path -- free-form surfaces machining; Factory management -- Periodicals; 658.57
• DOI: 10.1080/00207543.2018.1512763
• Languages: English
• ISSNs: 0020-7543

Abstract

Abstract : Machining of free-form surfaces has an important role in industrial manufacturing, but conventional tool-path generation strategies for free-form surfaces machining have the drawbacks of serious flattening distortion and poor tool-path continuity. Therefore, a novel method is developed to generate a spiral tool path for the machining of free-form surfaces by improving surface-flattening distortion and tool-path continuity. First, physical shell mapping is presented to flatten a free-form surface into a plane, which takes stretching energy, bending energy, and global energy into account. Then, the spatial spiral polyline is rounded to generate a spiral path by proposing reverse-compensation optimisation. Therefore, the free-form surfaces can be quickly flattened with less distortion, remaining free of overlap, and can in addition be machined at high speed along a C 2 continuous spiral tool path. Further, the flattening error, tool-path length, mean curvature, mean scallop-height error of the spiral path, machining time and surface roughness are obviously reduced. Finally, simulation results are given to show the effectiveness and feasibility of the presented strategy.