Development of practical postprocessor for 5-axis machine tool with non-orthogonal rotary axes

In order to develop a practical postprocessor for 5-axis machine tool,the general equations of numerically controlled(NC) data for 5-axis configurations with non-orthogonal rotary axes were exactly expressed by the inverse kinematics,and a windows-based postprocessor written with Visual Basic was developed according to the proposed algorithm.The developed postprocessor is a general system suitable for all kinds of 5-axis machines with orthogonal and non-orthogonal rotary axes.Through implementation of the developed postprocessor and verification by a cutting simulation and machining experiment,the effectiveness of the proposed algorithm is confirmed.Compatibility is improved by allowing exchange of data formats such as rotational total center position(RTCP) controlled NC data,vector post NC data,and program object file(POF) cutter location(CL) data,and convenience is increased by adding the function of work-piece origin offset.Consequently,a practical post-processor for 5-axis machining is developed.

Development of tool-path generation module for 5-axis control machining of impellers

An impeller is difficult to machine because of severe collision due to the complex shape,overlapping and twisted shape of the impeller blades.So,most computer aided manufacturing(CAM)software companies have developed CAM module for manufacturing impeller according to their CAM software.But these dedicated modules are difficult to use for inexperienced users.The purpose of this work is to develop a tool-path generation module for impellers.For this purpose,it is based on Visual Basic language and used CATIA graphical environment.The result of simulation for generated tool-path by the module is satisfactory.And it has slow processing speed compared to other commercial modules,but it is easy to use.

Determination of efficient superfinishing conditions for mirror surface finishing of titanium

To determine mirror surface finishing conditions and efficient and economical superfinishing conditions for pure titanium and titanium alloys, an abrasive film is used when superfinishing is performed under varying conditions. These conditions include the workpiece rotation speed, the oscillation speed, the contact pressure of the roller, the hardness of the roller, and the type of abrasive film. The superfinishing device is applied to polishing a thin and long cylindrical bar. A micro-finishing film and a lapping film were used as abrasive films. A1203 grains or SiC grains were used as abrasives. The surface roughness of a polished workpiece was measured using a stylus-type surface-roughness measuring instrument. As a result, the conditions to improve the polishing surface efficiently include high values for the workpiece rotation speed, oscillation speed and contact pressure. The roller hardness has no effect on the efficient polishing conditions. The mirror finish of a surface can be created using lapping film of 3 μm with Al2O3 grains after polishing to a steady surface roughness under the efficient polishing conditions.

Development of twin wheel creep-feed grinding machine using continuous dressing for machining of aircraft rotary wing

The purpose of this study is to develop a twin wheel creep-feed grinding machine using continuous dressing to machine precise axisymmetric turbine blades that have been difficult to machine using a conventional creep-feed machine.In order to develop such a machine,3D-modeling and machine simulations were performed and a twin wheel creep-feed grinding machine was manufactured.Furthermore,the axisymmetric precision of the machined workpieces through practical machining was evaluated and the quality of the continuous dressing effect of the developed machine was established.In addition,experimental considerations for a proper dresser-to-wheel speed ratio and proper feed rate of the dresser were carried out.As a result,a twin wheel creep-feed grinding machine with continuous dressing is developed through machine simulation,manufacturing and performance evaluation.Optimum condition for the dresser feed rate is 0.3μm/rev.In cases of large dressor-to-wheel speed ratio,grinding efficiency can be enhanced,but the surface roughness shows a conflicting trend.Developed twin wheel creep-feed grinding machine has satisfactory appraisal with regard to surface roughness,flatness,and parallelism.Satisfactory surface roughness below 0.1μm can be obtained for the blade of aircraft.However,in order to perform precise machining,it is necessary to improve the structure of the twin wheel creep-feed grinding machine.

Continuity control method of cutter posture vector for efficient five-axis machining

During five-axis machining of impeller, the excessive local interference avoidance leads to inconsistency of cutter posture, low quality of machined surface and increase of processing time. Therefore, in order to improve the efficiency of five-axis machining of impellers, it is necessary to minimize the cutter posture changes and create a continuous tool path while avoiding interference. By using an MC-space algorithm for interference avoidance, an MB-spline algorithm for continuous control was intended to create a five-axis machining tool path with excellent surface quality and economic feasibility. A five-axis cutting experiment was performed to verify the effectiveness of the continuity control. The result shows that the surface shape with continuous method is greatly improved, and the surface roughness is generally favorable. Consequently, the effectiveness of the suggested method is verified by identifying the improvement of efficiency of five-axis machining of an impeller in aspects of surface quality and machining time.