The conventional prediction of milling stability has been extensively studied based on the assumptions that the milling process dynamics is time invariant. However, nominal cutting parameters cannot guarantee the stability of milling process at the shop floor level since there exists many uncertain factors in a practical manufacturing environment. This paper proposes a novel numerical method to estimate the upper and lower bounds of Lobe diagram, which is used to predict the milling stability in a robust way by taking into account the uncertain parameters of milling system. Time finite element method, a milling stability theory is adopted as the conventional deterministic model. The uncertain dynamics parameters are dealt with by the non-probabilistic model in which the parameters with uncertainties are assumed to be bounded and there is no need for probabilistic distribution densities functions. By doing so, interval instead of deterministic stability Lobe is obtained, which guarantees the stability of milling process in an uncertain milling environment. In the simulations, the upper and lower bounds of Lobe diagram obtained by the changes of modal parameters of spindle-tool system and cutting coefficients are given, respectively. The simulation results show that the proposed method is effective and can obtain satisfying bounds of Lobe diagrams. The proposed method is helpful for researchers at shop floor to making decision on machining parameters selection.
A novel approach of iso-scallop trajectory generation for smooth manifold surfaces has been developed. Firstly,by defining homeomorphism mapping relations and differentiable structures,the smooth manifold surface is mapped into several Euclidean planes,thus its trajectory generation can be decomposed into planar curve-filling tasks. Secondly,in the generation of direction-parallel trajectories,the calculation of the cutting interval and the curvature is given,depending on the generation of the first curve in the projection view. Thirdly,after automatic adherences of inverse projection curves,the filled curves are mapped into the original surface inversely to form trajectories. Although the required trajectories are iso-scallop,the trajectory intervals are variable according to the curvature changes at the projection point,which is advantageous to improving the trajectory quality. The proposed approach has appealing merits of dimensionality reduction,which decreases the algorithm complexity. Finally,numerical and machining examples are given to illustrate its feasibility and validity.
Automatic localization,aligning the measured points with the design model,is a basic task in free-form surface inspection.The main difficulty of current localization algorithms is how to define effective distance function and localization reliability index.This paper proposes a new method of calculating motion parameters and evaluating localization reliability.First,improved modified coefficient is defined and applied to weighted-iteration distance function,which better approximates the point-to-surface closest distance.It can control the contribution ratios of different measured points by considering the curvature feature and iterative residual.Second,the mapping relationship between localization error and geometric error is analyzed,from which a Lyapunov-test statistic is derived to define a frame-independence index.Then,the determination of localization reliability changes into a supposition examination problem.This can avoid rejecting correct motion parameters,which exists in the traditional judgment of absolute root-mean-square distance.In addition,two test experiments are implemented to demonstrate the proposed localization algorithm.
In this paper, the geometric properties of a pair of line contact surfaces are investigated. Then, based on the observation that the cutter envelope surface contacts with the cutter surface and design surface along the characteristic curve and cutter contact (CC) path, respectively, a mathematical model describing the third-order approximation of the cutter envelope surface according to just one given cutter location (CL) is developed. It is shown that at the CC point both the normal curvature of the normal section of the cutter envelope surface and its derivative with respect to the arc length of the normal section can be determined by those of the cutter surface and design surface. This model characterizes the intrinsic relationship among the cutter surface, cutter envelope surface and design surface in the neighborhood of the CC point, and yields the mathematical foundation for optimally approximating the cutter envelope surface to the design surface by adjusting the cutter location.
ZHU LiMin1, DING Han2 & XIONG YouLun2 1 State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, Shanghai 200240, China
Based on the mathematical model describing the third-order approximation of the cutter envelope surface according to one given cutter location(CL),a tool positioning strategy is proposed for efficiently machining free-form surfaces with non-ball-end cutters.The optimal CL is obtained by adjusting the inclination and tilt angles of the cutter until its envelope surface and the design surface have the third-order contact at the cutter contact(CC)point,which results in a wide machining strip.The strategy can handle the constraints of machine joint angle limits,global collision avoidance and tool path smoothness in a nature way,and can be applied to general rotary cutters and complex surfaces.Numerical examples demonstrate that the third-order point contact approach can improve the machining strip width greatly as compared with the recently reported second-order one.
ZHU LiMin 1 ,DING Han 2 &XIONG YouLun 2 1State Key Laboratory of Mechanical System and Vibration,Shanghai Jiao Tong University,Shanghai 200240,China
This paper studies representation of rigid combination of a directed line and a reference point on it(here referred to as a "point-line") using dual quaternions.The geometric problem of rational ruled surface design is viewed as the kinematic prob-lem of rational point-line motion design.By using the screw theory in kinematics,mappings from the spaces of lines and point-lines in Euclidean three-dimensional space into the hyperplanes in dual quaternion space are constructed,respectively.The problem of rational point-line motion design is then converted to that of projective Bézier or B-spline image curve design in hyperplane of dual quaternions.This kinematic method can unify the geometric design of ruled surfaces and tool path gen-eration for five-axis numerical control(NC) machining.
