Title: Simulation of the behaviour of CNC machine-tools in three-axis milling of sculptured surfaces

Authors: Xavier Pessoles, Yann Landon, Michel Mousseigne, Walter Rubio

Addresses: Universite de Toulouse, INSA, UPS, Mines Albi, ISAE, ICA (Institut Clement Ader), 135, Avenue de Rangueil, F-31077 Toulouse, France. ' Universite de Toulouse, INSA, UPS, Mines Albi, ISAE, ICA (Institut Clement Ader), 135, Avenue de Rangueil, F-31077 Toulouse, France. ' Universite de Toulouse, INSA, UPS, Mines Albi, ISAE, ICA (Institut Clement Ader), 135, Avenue de Rangueil, F-31077 Toulouse, France. ' Universite de Toulouse, INSA, UPS, Mines Albi, ISAE, ICA (Institut Clement Ader), 135, Avenue de Rangueil, F-31077 Toulouse, France

Abstract: Three-axis high-speed machining (HSM) of sculptured surfaces is currently programmed with linear or B-spline interpolation using CAM software. In both cases, due to axis dynamic limits of the CNC machine-tools, the desired feed rate is rarely reached, leading to lower productivity and impaired quality. In order to allow an optimisation of the process, a simulator is proposed in this paper. Changes in position, velocity, acceleration and jerk of each axis during three-axis HSM operations are modelled, based on a trapezoidal acceleration scheme. The relative speed between tool and workpiece is then computed for linear segments as for B-spline paths. Transitions between segments are also simulated. The three-axis simulator is experimentally validated through machining of a turbine blade.

Keywords: high speed machining; HSM; sculptured surfaces; CNC machining; machine tool dynamics; simulation; three-axis milling; feed rate; trapezoidal acceleration; modelling; turbine blades.

DOI: 10.1504/IJMMM.2010.036142

International Journal of Machining and Machinability of Materials, 2010 Vol.8 No.3/4, pp.326 - 338

Published online: 22 Oct 2010 *

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