A radius compensation method of barrel tool based on macro variables in five-axis flank machining of sculptured surfaces

Rufeng Xu, Xun Li, Guangming Zheng, Xiang Cheng and Yebing Tian

International Journal of Production Research, 2020, vol. 58, issue 8, 2335-2351

Abstract: Barrel tool radius compensation is very important to improve the five-axis CNC machining precision and efficiency of sculptured surfaces. By combining macro variables and math function of CNC controller, a radius compensation method of barrel tool based on macro variables in five-axis flank machining of sculptured surfaces was presented. The basic principle of barrel tool radius compensation in five-axis flank machining was firstly investigated. For a specific five-axis CNC machine tool with dual rotary tables, a relationship equation between compensated cutter location (CL) data and machine control (MC) data could be derived. A post-processor with the function of five-axis barrel tool radius compensation was then developed by using the C++ language, which could generate the NC programme with macro variables of barrel tool radius compensation. Finally, the NC programme was obtained automatically by the developed post-processor for the aero-engine blade surface machining. The machining process was simulated on the software VERICUT, and machining experiments were also conducted on the five-axis machine tool. Both the simulation and experimental results showed that the proposed method could perform the function of barrel tool radius compensation in the NC programme for five-axis flank machining.

Date: 2020
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DOI: 10.1080/00207543.2019.1627437

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