Automatic Generation of Milling Toolpaths with Tool Engagement … · 2010. 10. 1. · However,...
Transcript of Automatic Generation of Milling Toolpaths with Tool Engagement … · 2010. 10. 1. · However,...
Automatic Generation of Milling Toolpaths with ToolEngagement Control for Complex Part Geometry
Alexandru Dumitrache Theodor Borangiu Anamaria Dogar
Centre for Research & Training in Industrial ControlRobotics and Materials EngineeringUniversity Politehnica of Bucharest
IMS 2010
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Outline
1 Overview3D Laser Scanning SystemCNC milling issuesTool Engagement Angle
2 Related work
3 Proposed algorithm and experimental resultsMilling parts for algorithm evaluationTraditional toolpathsProposed algorithmResults
4 Conclusions
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3D Laser Scanning System Overview
Robot Controller Rotary table controller
4-Axis CNC Milling Machine
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Data acquisition module (PC)
Instantaneous encoder positions
Laser probe location with respect to
scanned workpiece
USB
Point Cloud COM
PC
6-DOF VerticalRobot Arm
Laser probe
Rotary table
Scanned workpiece
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3D Laser Scanning System Overview
6-DOF ArticulatedRobot Arm
4-Axis CNCMilling Machine
Laser Probe
Scanned Workpiece
Rotary Table
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Main issues for CNC milling
CNC millingAutomatic CNC toolpath generationMilling parts with complex geometryMinimizing CNC milling time without overheating the cutting tool
Proposed solutionDepth map modelling of design part and raw stockNatural representation for 2.5D milling operationCan be extended to 4-axis milling
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Tool Engagement Angle
The amount of sweep subentended by each cutting edgeas it engages and leaves the stockProportional to the cutting forcesIt is known to increase at internal corners in the toolpath
r
D
Milling tool Raw stock Tool engagement
∗
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Tool Engagement Angle←→ Stepover
On straight line toolpaths, TEA (θ ) is proportional to stepover (s):
s =1+ sin(θ −90◦)
2, 0≤ θ ≤ 180◦ (1)
θ = 90◦+ arcsin(2s−1) , 0≤ s≤ 1 (2)
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Stepover (%)
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Related work
Coleman (2006) explains the problem well, with intuitive examplesStori and Wright (2000): modified offset toolpath for convexcontoursBieterman (2001) replaced contour-parallel toolpaths with asmooth spiral, nearly circular at pocket center, and slowlymorphing into the part shape as it gets closer to the partIbaraki et al. (2004) removed the convexity requirement fromStory and Wright’s approachWang et al. (2005) defined a set of quantifiable metrics which canbe obtained by pixel simulationUddin et al. (2006) applied the Ibaraki’s approach for improvingtolerance on the finishing part by offsetting it nonuniformly, so thatthe finishing step is done at constant tool engagementRauch et al. (2009): constraints-based trochoidal toolpaths
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Milling parts for algorithm evaluation
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Milling parts – depth map representation
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Traditional toolpaths
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Direction-parallel toolpaths
Contour-parallel toolpaths
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Trochoidal Step (SprutCam v7)
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Contour-parallel toolpaths
Contour-parallel toolpaths with trochoidal step
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Trochoidal Step (SprutCam v7)
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Contour-parallel toolpaths
Contour-parallel toolpaths with trochoidal step
Tool engagement peak
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Trochoidal Step (SprutCam v7)
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Contour-parallel toolpaths
Contour-parallel toolpaths with trochoidal step
Tool engagement peak
Tool engagement decreased
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Trochoidal Step for Complex Geometry (SprutCam v7)
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Contour-parallel toolpaths
Contour-parallel toolpaths with trochoidal step
Tool engagement peaks are still present!
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Trochoidal Step for Complex Geometry (SprutCam v7)
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Contour-parallel toolpaths
Contour-parallel toolpaths with trochoidal step
Tool engagement peaks are still present!
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Proposed algorithm
InputTool diameterPrescribed tool engagement angleBinary image representing the design part (2D section)Binary image representing the raw stock (2D section)The 2D sections can be obtained by thresholding a 3D depth map
Output2D milling toolpaths consisting of small linear segmentsRaw stock shape after the generated milling operation
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Proposed algorithmC
ontourreached
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Found point
outside contour
ContouringFound pointon the contour
No points
found
No circumference pixels engaged
All contour points visited
Constant Engagement
Start
Stop
Find Starting Point
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Constant Engagement Milling
Main section of the algorithmMilling a raw stock with arbitrary shapeThe only constraint is the tool engagement angleThe raw stock shape is updated at every step
Engagement
Milling cutter
Previous trajectoryAdvancing directionAdvancing direction for 90o TEA: Previous advancing
direction:
0o360o
270o
Intersection point
90o−ref
p
90climb
90oRawstock
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Constant Engagement Milling
Example: toolpath with constant engagement for arbitrary raw stock shape
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Contour Milling
Contour MillingTool moves along the offset contourTool is always tangent to the design pathUsually, tool engagement angle is much smaller than theprescribed value
Stop conditionsWhen TEA exceeds the prescribed value with more than a smallthreshold, the algorithm switches to Constant Engagement modeWhen all contour points are visited, the algorithm will search for anew starting point
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Contour Milling
Example: Contour milling for the test part
Direction for constant engagement
Direction for contour milling
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Contour Milling
Tool engagement angle exceeded the prescribed value
Direction for constant engagement
Direction for contour milling
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Contour Milling
The algorithm switched to constant engagement milling
Direction for constant engagement
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Contour Milling
The algorithm switched to constant engagement milling
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Finding Starting Point
The first possibility is chosen from the following:1 Continue a contouring operation, from the point where the
algorithm switched from Contouring to Constant Engagement2 Enter the raw stock horizontally, from lateral3 Plunge the cutter into raw stock
InputCurrent cutter position: (x0,y0)Current raw stock and part shapes (2D images)
OutputStarting point for next milling operation: (x,y)Milling trajectory for moving the cutter to (x,y):
Cutter retraction moves or tangent / plunge entry toolpaths
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Example movie
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Results – 37◦ engagement
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Results – 60◦ engagement
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Results – 90◦ engagement
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Results – 120◦ engagement
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Results – 60◦ engagement
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Results – 90◦ engagement
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Results – 120◦ engagement
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Results – 135◦ engagement
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Sharp corners
Sharp cornersThe generated toolpath may contain external cornersThese corners do not cause an increase in the tool engagementHowever, they are not good for machine dynamicsCorners are smoothed by the machine controller, with G64
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Sharp corners
Sharp cornersThe generated toolpath may contain external cornersThese corners do not cause an increase in the tool engagementHowever, they are not good for machine dynamicsCorners are smoothed by the machine controller, with G64
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Sharp corners
Sharp cornersThe generated toolpath may contain external cornersThese corners do not cause an increase in the tool engagementHowever, they are not good for machine dynamicsCorners are smoothed by the machine controller, with G64
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Results
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Results
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Conclusions
2D toolpath generation with tool engagement controlPrescribed reference value for engagement angleMaximum allowed overshoot (default: 20◦)
Toolpath consists of small linear segmentsSuitable for arbitrarily complex part and raw stock geometryRaw stock geometry can be digitized with 3D scanningReduces lubrication requirements and increases tool lifeHigher feed rates can be used, compared to traditional toolpathsBest results are obtained using this method for roughing,combined with the method from (Uddin et al., 2006) for finishingThe algorithm is used for milling complex 3D surfaces on millingmachines with 3 or 4 axes
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