Smooth surface finishing for 5-axis flank CNC machining of free-form geometries using custom-shaped tools

Kód výsledku v IS VaVaI

<a href="https://www.isvavai.cz/riv?ss=detail&h=RIV%2F49777513%3A23520%2F25%3A43975629" target="_blank" >RIV/49777513:23520/25:43975629 - isvavai.cz</a>

Výsledek na webu

<a href="https://doi.org/10.1016/j.cad.2025.103887" target="_blank" >https://doi.org/10.1016/j.cad.2025.103887</a>

DOI - Digital Object Identifier

<a href="http://dx.doi.org/10.1016/j.cad.2025.103887" target="_blank" >10.1016/j.cad.2025.103887</a>

Jazyk výsledku

angličtina

Název v původním jazyce

Smooth surface finishing for 5-axis flank CNC machining of free-form geometries using custom-shaped tools

Popis výsledku v původním jazyce

Geometric modeling is traditionally a key part of an efficient manufacturing pipeline as one can decide, in virtual realm, what specific manufacturing tools to use and how to move them. Flank milling is the finishing stage of 5-axis Computer Numerically Controlled (CNC) machining, a stage where the machining accuracy is equally important as the smooth surface finish of the to-be-manufactured workpiece. The benchmark machining geometries such as propellers or blisks are doubly-curved surfaces and one typically needs several paths of the tool to get highly accurate surface finish. However, navigating a tool to move tangentially (i.e., in flank fashion) to the surface is very restrictive and in order to get highly accurate approximation, one typically has to compromise the smoothness across the neighboring paths.To connect neighboring paths in smooth ($G^1$-continuous) fashion using a conical tool is possible only for reasonably flat target geometries, such as spiral bevel gears, however, for a general free-form surface conical tools do not offer sufficient degrees of freedom. In this work, we consider generally curved, custom-shaped, cutting tools, whose shape is a design parameter computed by the proposed optimization-based framework to adapt their motions globally to the input free-form surface, supporting a feature of $G^1$ connection across the neighboring paths. We demonstrate our algorithm on synthetic free-form surfaces as well as on industrial benchmark datasets, showing that optimizing the shape of the tool offers more flexibility to produce $G^1$ connections between neighboring strips and outperforms conical tools both in terms of the approximation error and the smoothness.

Název v anglickém jazyce

Smooth surface finishing for 5-axis flank CNC machining of free-form geometries using custom-shaped tools

Popis výsledku anglicky

Geometric modeling is traditionally a key part of an efficient manufacturing pipeline as one can decide, in virtual realm, what specific manufacturing tools to use and how to move them. Flank milling is the finishing stage of 5-axis Computer Numerically Controlled (CNC) machining, a stage where the machining accuracy is equally important as the smooth surface finish of the to-be-manufactured workpiece. The benchmark machining geometries such as propellers or blisks are doubly-curved surfaces and one typically needs several paths of the tool to get highly accurate surface finish. However, navigating a tool to move tangentially (i.e., in flank fashion) to the surface is very restrictive and in order to get highly accurate approximation, one typically has to compromise the smoothness across the neighboring paths.To connect neighboring paths in smooth ($G^1$-continuous) fashion using a conical tool is possible only for reasonably flat target geometries, such as spiral bevel gears, however, for a general free-form surface conical tools do not offer sufficient degrees of freedom. In this work, we consider generally curved, custom-shaped, cutting tools, whose shape is a design parameter computed by the proposed optimization-based framework to adapt their motions globally to the input free-form surface, supporting a feature of $G^1$ connection across the neighboring paths. We demonstrate our algorithm on synthetic free-form surfaces as well as on industrial benchmark datasets, showing that optimizing the shape of the tool offers more flexibility to produce $G^1$ connections between neighboring strips and outperforms conical tools both in terms of the approximation error and the smoothness.

Druh

J_imp - Článek v periodiku v databázi Web of Science

CEP obor

—

OECD FORD obor

10102 - Applied mathematics

Projekt

<a href="/cs/project/EH23_021%2F0008436" target="_blank" >EH23_021/0008436: VaV technologií pro pokročilou digitalizaci v plzeňské metropolitní oblasti (DigiTech)</a><br>

Návaznosti

P - Projekt vyzkumu a vyvoje financovany z verejnych zdroju (s odkazem do CEP)<br>I - Institucionalni podpora na dlouhodoby koncepcni rozvoj vyzkumne organizace

Rok uplatnění

2025

Kód důvěrnosti údajů

S - Úplné a pravdivé údaje o projektu nepodléhají ochraně podle zvláštních právních předpisů

Název periodika

Computer-Aided Design

ISSN

0010-4485

e-ISSN

1879-2685

Svazek periodika

185

Číslo periodika v rámci svazku

AUG 2025

Stát vydavatele periodika

NL - Nizozemsko

Počet stran výsledku

12

Strana od-do

nestránkováno

Kód UT WoS článku

001484890400001

EID výsledku v databázi Scopus

2-s2.0-105003874205