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Material left cleaning operation
In TOPSOLID CAM for 3D Machining
Jayasimha Bagalkote
SAGA Initial Training Network.
Winter school - Auron, France.15-19 March.
MISSLER SOFTWARE
15 March, 2010
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Outline
• Introduction of MISSLER Software and short demonstration of
TOPSOLID.
• Clean up Machining Description
• Tools used in Machining.
• Approaches for Cutter Location points calculation.
• Material left removal operation steps and sample results.
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MISSLER SOFTWARE
Missler Software is an Industrial Partner participating in the SAGA Initial
Training Network.
Missler Software is a leading global supplier of CAD, CAM and ERP
solutions.
The company has been in operation for more than 20 years and is
classified as one of the leading CAD/CAM developers worldwide.
Missler Software offers an integrated solution for the mechanical
industry (general mechanical design, special machinery, tool and die,
subcontracting industries…) with its product lines TopSolid and GOelan.
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TOPSOLID: An Introduction
• Mechanical Engineering
TopSolid'Design, TopSolid'Cam
• Product Design
TopSolid'Design, TopSolid'Draft
• Machining
TopSolid'Cam, TopSolid'Wire, TopSolid'PunchCut
• Tool making
TopSolid'Mold, TopSolid'Progress,
TopSolid'Electrode
• Sheet metal
TopSolid'Fold, TopSolid'PunchCut
• Wood working
TopSolid'Wood, TopSolid'WoodCam
• Management
TopSolid’Pdm
• ERP
TopSolid’Erp
TopSolid’Erp is a fully integrated ERP system which
responds to all supply chain requirements
from commercial to production management. TopSolid’Erp
offers a complete solution for the
following areas: Commercial administration, management
of technical data, shop floor management, client support
and PDM (Product Data Management) TopSolid’Erp is
fully integrated with the TopSolid CAD/CAM range of
products, thus allowing full integration between all
company departments.
TopSolid is an integrated CAD/CAM/ERP solution for the design and manufacture of products
in diverse domains of activity: machines, plastic parts, tools, sheet metal, general mechanical
engineering, wood working, etc. TopSolid is a single-source software solution that can be used
to effectively meet all design, production and company-specific manufacturing control requi-
rements.
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Clean-up Machining or
Material left Removal Operation
The clean-up machining discussed is pencil-cut and fillet-cut
for a polyhedralmodel of the STL form with a ball-endmill.
The Pencil points are obtained from the Parallel cutting
planes on the xz, yz,and xy planes.
The purpose is to generate Pencil-point curve and then to
generate the fillet-cut path in order to remove uncut
volumes, which are left at concave regions after finish
Machining , by employing ball end-mills of the same or
smaller sizes.
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Figures
Fig: Tool path generation for clean-up machining.
a) Uncut Volumes (Material left)
b) Pencil-cut
c) Fillet-cutThe name comes from the way that a pencil could naturally be drawn along these corners.
It's sometimes called a rolling ball toolpath6
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Tools used in Machining
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Tools used in Machining
The machining operation is commonly perfomed by 3-axis milling using ball-end mills because
they are more easily positioned with respect to design surface and therefore results in
Simpler NC code to machine the surface. Though 5-axis flat end milling offers many advantages,
including faster material removal rates and improved surface finish,it has a number of drawbacks,
such as motion specification and collision avoidance.3-axis milling is relatively cheap, commonly
available and suitable for surfaces with high curvature variations.
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Gouge points
Fig: Problem of Detecting Gouge points in Point to Point based tool path
generation.
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Offsets
Offset curves are defined as the
locus of the points which are at a constant distance d
along the normal from the
generator curve.
let C(t) = (Cx(t),Cy(t)) be the curve for parameter t.
Then Coffset(t) = C(t) + d.N(t)
The unit Normal N(t) =
However facets are used to generate offsets in our
case.10
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Offsets of vertices in Polyhedral
Models
Offsets when ball-end mill is
used.
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Example
Fig : An example of the parallel-cutting planes method for a polyhedral model
(a)A polyhedralmodel. (b)Thelocal-offsetmodel.
(c)Untrimmed CL-curves (Cutter Location) (d)CL-paths. (Cutter Location paths)12
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Steps for Material Left Removal
Operation
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Steps for Material Left Removal
Operation•Parallel drive planes cutting the STL model in each of XZ, YZ, and XY planes.
Discretized Scanning line and projection on to the faceted offset shape.
Smoothening of the curve linking the projected points for each line, using tangent
vector of each point with that of the next point.
(Looking for closed curves in case of XZ plane)
• Detecting Pencil points.
Compare the tangent vectors of each point with that of the next.
Compare the normal vector of the next point with the previous point and the successive
point.
Check for material left condition using the middle point ( the candidate for Pencil point )
Create the Pencil point with the two normal vectors.
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Sample Results: Cuts on Part
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XY Drive plane cuts to detect nearly Vertical Pencil
point curves
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Pencil point
Fig: Pencil point detection. Each Pencil point has two Normal vectors to the faceted Shape. Angular
tolerancy is the primary measure used in detection. Material left check is a more stringent check which is
computationally time-consuming.17
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Steps for Material Left Removal
Operation•Linking of Pencil points to get a Pencil Curve
Pencil points are stored separately according the cuts( drive planes) that
generated them.
For each such stored list , look for a starting Pencil point and proceed
to look for the next point to be linked along its own cut and along the
immediate neighbouring ‘grid lines’ which results in searching for linkable
points in a cuboid.
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Pencil point Curve for later use
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Fillet-Cut: Future work
Fig: Fillet-Cut path generation for removing the material left by previous
operations.
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Pencil points from XY drive plane cuts
And Material left curves display.
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Linking of Pencil points(work in progress)
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Close up of Linking of Pencil-points
Presentation Title 3/22/2010 23
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Acknowledgments
SAGA Initial Training Network FP7-PEOPLE-2007-1-1-ITN
(2008-2012).
Mr. Yvan Roche
Development Engineer, Missler Software.
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References
[1] Duncan J.P, Mair S.G. Sculptured surfaces in engineering and medicine. USA:CambridgeUniversityPress;1983.
[2] Hwang J.S. Interference-free tool-path generation in the NC machining of parametric compound surfaces.
Comput-AidDes1992;24(12):667–76.
[3] Choi B.K, Jerard R.B. Sculptured surface machining:theory and applications. Dordetch: Kluwer Academic;1998.
[4] Jun C.S, Kim D.S, Park S. A new curve-based approach to polyhedral machining. Comput-AidDes2002;34(5):379–89.
[5] Kim D.S. A curve-based approach to polyhedral model machining
PhD Thesis, Gyeongsang National University;2002, Korea.
[6] Park J.W, Kim B.H, Choi B.K. Pencil curve tracing via virtual digitizing. TransSocCAD/CAMEngs1997;2(4):253–66.
[7] Choi B K, Jun C.S. Ball-end cutter interference avoidance in NC machining of sculptured surfaces.
Comput-AidDes1989;21(6):371–8.
[8] RenY, Yau H.T, LeeY.S. Clean-up toolpath generation by contraction Tool method for machining complex polyhedral models
ComputIndus 2004;54(1):17–33
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Thank you
Presentation Title 3/22/2010 26