| Generating complex surface finish machining toolpath is a difficult task, and has been a focus of recent research. Machining accuracy, machining efficiency, tool life and surface quality all depend on the quality of the tool path generation algorithm. Gouging have bad effects on CNC machining, such as reduction of tool life, accuracy of the surface, damage of machining tool. The toolpath generated by CAM software cannot be applied in machining because of gouging, so engineers have to change the cutter and the machining process.Aiming at complex surface machining, and based on the traditional milling cutter projection algorithm and cutter partition, this paper provides an algorithm of detection and elimination of gouging and tool axis optimization for five-axis and four-axis. This paper presents detection and elimination of both local gouging and rear gouging, in five-axis machining using any milling tools. The gouging checking method based on projection and cutter partition can improve accuracy. The projection algorithm solves the local gouging and the tool rotation method solves the rear gouging. A tool axis optimization method is proposed to find the optimal tool orientation for the purpose of machining with the leading edge of the cutter. Computer simulation and examples are also provided in the paper.The result indicates that the algorithm can be used to generate toolpath to machine workpiece with complex compound surfaces due to high machining accuracy and machining surface quality. The algorithm is suitable for all kinds of six parameter milling cutter. It satisfies the high-precision requirements of the engineering company. It also has great significance on the CAM software development for machining the workpiece with complex compound surfaces and save the money used to buy the sophisticated CAM software from foreign country.In order to verify the algorithm, turbine blade, as one typical workpieces with complex compound surfaces, machining process is simulated. By adjusting the cutting parameters and modifying the cutter parameters, we use the CAM software that integrated the gouging avoidance algorithm to generate toolpath then check and eliminate the gouging. We also use the software UGNX to analyze the toolpath. The result shows that there is little gouge or undercut, the machining error is less than510-mm and the tool path is smoothing. |
