Research on Cutter Path Generation for 5-Axis U Cycloid Milling Based on Dimension Reduction Mapping

doi:10.3901/JME.2024.05.362

Abstract

Abstract: As an important part of NC machining, cutter path generation is a complex system including many factors such as milling mode, tool workpiece structure and machining allowance. U cycloid milling is a cutter path strategy that integrates the advantages of cycloid milling and flank milling. It can complete rough machining with large axial cutting depth. The cutter path form of gentle cut in and cut out can effectively stable the cutting force and the local load is dispersed. Aiming at the flow path of integral impeller, a cutter path generation method for U cycloid milling based on dimension reduction mapping is proposed. The geometric model of U cycloid milling is established, the cycloid feature parameters are defined, and the calculation method of cycloid residue is given. According to the rule of tool motion, the path is discretized into a series of micro elements. Based on the intersection of the tool and the previous cutter path, the path is divided into multiple regions, and the calculation methods of the cutter-workpiece wrap angle under the corresponding cycloidal position angle are obtained respectively. Combined with U cycloid milling features, the milling boundary preprocessing method is established. Considering the complexity of cutter path calculation in 3D space, the space geometry domain and dimension reduction parameter domain are defined. On this basis, the dimension reduction mapping method of tiled small arc segment is given and the dimension reduction paths are calculated in different cycloid intervals. In order to obtain interference free U cycloid milling cutter axis vector, a double-action ratio domain mapping algorithm is established by using the isoparametric equation, and arbitrary vector inverse mapping is realized by solving a series of deflection angles. Finally, the trajectory matrix is coded into general machine tool language, and the feasibility of the strategy is verified through simulation studies and milling experiments.

Key words: U cycloid milling, dimension reduction mapping, cutter-workpiece wrap angle, 5-axis milling, cutter path

CLC Number:

TG506

FENG Jingyang, WEI Zhaocheng, WANG Minjie, SHU Xin, ZHANG Yong, YONG Jianhua. Research on Cutter Path Generation for 5-Axis U Cycloid Milling Based on Dimension Reduction Mapping[J]. Journal of Mechanical Engineering, 2024, 60(5): 362-377.

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