The machining industry must maximize the machine tool utilization for its efficient and effective usage. Determining a feasible workpiece location is one of the significant tasks performed in an iterative way via mach...The machining industry must maximize the machine tool utilization for its efficient and effective usage. Determining a feasible workpiece location is one of the significant tasks performed in an iterative way via machining simulations. The maximum utilization of five-axis machine tools depends upon the cutting system’s geometry, the configuration of the machine tool, and the workpiece’s location. In this research, a mathematical model has been developed to determine the workpiece’s feasible location in the five-axis machine tool for avoiding the number of iterations, which are usually performed to eliminate the global collision and axis limit errors. In this research, a generic arrangement of the five-axis machine tool has been selected. The mathematical model of post-processor has been developed by using kinematic modeling methods. The machine tool envelopes have been determined using the post-processor and axial limit. The tooltip reachable workspace is determined by incorporating the post-processor, optimal cutting system length, and machining envelope, thereby further developing an algorithm to determine the feasible workpiece setup parameters accurately. The algorithm’s application has been demonstrated using an example. Finally, the algorithm is validated for feasible workpiece setup parameters in a virtual environment. This research is highly applicable in the industry to eliminate the number of iterations performed for the suitable workpiece setup parameters.展开更多
The cutter systems of hypoid gear cutting machines contain groups of inside and outside blades.In these cutter systems,the side cutting edges of the blades machine the convex and concave gear teeth while rotating abou...The cutter systems of hypoid gear cutting machines contain groups of inside and outside blades.In these cutter systems,the side cutting edges of the blades machine the convex and concave gear teeth while rotating about the cutter rotation axis.The side cutting edges lay on the rake face formed through the blade,rake,and relief angles;hence,the normal cross-section of the cutter swept surface forms hyperboloid gear teeth.Using the accurate geometry of the cutter system,a relationship between the pressure and spiral angles of the gear tooth and the parameters of the cutter system is developed for the FORMAT machining of a hypoid gear.A new parameterization of the gear tooth surfaces is introduced to determine these angles for the accurate gear tooth by the accurate cutter system.A numerical example with different cutter systems and blade parameters is presented,demonstrating the effects of rake and relief angles over the pressure and spiral angles on mea n point projections and gear tooth surface.Finally,the change in pressure and spiral angles with respect to the rake and relief angles are plotted,and the results are analyzed.Finally,it is concluded that the pressure and spiral angles are changed up to a few seconds of a degree in the operating area of the tooth with the change in the back and side rake angles.The side relief angle exhibited little or no effect over the geometry of the gear tooth.展开更多
基金The funding of the research project was provided by NED University of Engineering and Technology,Pakistan.
文摘The machining industry must maximize the machine tool utilization for its efficient and effective usage. Determining a feasible workpiece location is one of the significant tasks performed in an iterative way via machining simulations. The maximum utilization of five-axis machine tools depends upon the cutting system’s geometry, the configuration of the machine tool, and the workpiece’s location. In this research, a mathematical model has been developed to determine the workpiece’s feasible location in the five-axis machine tool for avoiding the number of iterations, which are usually performed to eliminate the global collision and axis limit errors. In this research, a generic arrangement of the five-axis machine tool has been selected. The mathematical model of post-processor has been developed by using kinematic modeling methods. The machine tool envelopes have been determined using the post-processor and axial limit. The tooltip reachable workspace is determined by incorporating the post-processor, optimal cutting system length, and machining envelope, thereby further developing an algorithm to determine the feasible workpiece setup parameters accurately. The algorithm’s application has been demonstrated using an example. Finally, the algorithm is validated for feasible workpiece setup parameters in a virtual environment. This research is highly applicable in the industry to eliminate the number of iterations performed for the suitable workpiece setup parameters.
文摘The cutter systems of hypoid gear cutting machines contain groups of inside and outside blades.In these cutter systems,the side cutting edges of the blades machine the convex and concave gear teeth while rotating about the cutter rotation axis.The side cutting edges lay on the rake face formed through the blade,rake,and relief angles;hence,the normal cross-section of the cutter swept surface forms hyperboloid gear teeth.Using the accurate geometry of the cutter system,a relationship between the pressure and spiral angles of the gear tooth and the parameters of the cutter system is developed for the FORMAT machining of a hypoid gear.A new parameterization of the gear tooth surfaces is introduced to determine these angles for the accurate gear tooth by the accurate cutter system.A numerical example with different cutter systems and blade parameters is presented,demonstrating the effects of rake and relief angles over the pressure and spiral angles on mea n point projections and gear tooth surface.Finally,the change in pressure and spiral angles with respect to the rake and relief angles are plotted,and the results are analyzed.Finally,it is concluded that the pressure and spiral angles are changed up to a few seconds of a degree in the operating area of the tooth with the change in the back and side rake angles.The side relief angle exhibited little or no effect over the geometry of the gear tooth.
