Combining physical shell mapping and reverse-compensation optimisation for spiral machining of free-form surfaces

Xiongbing Li, Zhiping Liu, Fulin Wang, Bing Yi and Yongfeng Song

International Journal of Production Research, 2019, vol. 57, issue 13, 4118-4131

Abstract: Machining of free-form surfaces has an important role in industrial manufacturing, but conventional tool-path generation strategies for free-form surfaces machining have the drawbacks of serious flattening distortion and poor tool-path continuity. Therefore, a novel method is developed to generate a spiral tool path for the machining of free-form surfaces by improving surface-flattening distortion and tool-path continuity. First, physical shell mapping is presented to flatten a free-form surface into a plane, which takes stretching energy, bending energy, and global energy into account. Then, the spatial spiral polyline is rounded to generate a spiral path by proposing reverse-compensation optimisation. Therefore, the free-form surfaces can be quickly flattened with less distortion, remaining free of overlap, and can in addition be machined at high speed along a C2 continuous spiral tool path. Further, the flattening error, tool-path length, mean curvature, mean scallop-height error of the spiral path, machining time and surface roughness are obviously reduced. Finally, simulation results are given to show the effectiveness and feasibility of the presented strategy.

Date: 2019
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DOI: 10.1080/00207543.2018.1512763

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