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Frontiers of Mechanical Engineering

ISSN 2095-0233

ISSN 2095-0241(Online)

CN 11-5984/TH

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Front. Mech. Eng.    2021, Vol. 16 Issue (2) : 298-314    https://doi.org/10.1007/s11465-020-0621-3
RESEARCH ARTICLE
Determination of the feasible setup parameters of a workpiece to maximize the utilization of a five-axis milling machine
Aqeel AHMED1, Muhammad WASIF1(), Anis FATIMA1, Liming WANG2, Syed Amir IQBAL1
1. Department of Industrial and Manufacturing Engineering, NED University of Engineering and Technology, Karachi 75270, Pakistan
2. School of Mechanical Engineering, Shandong University, Jinan 250061, China
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Abstract

The machining industry must maximize the machine tool utilization for its efficient and effective usage. Determining a feasible workpiece location is one of the significant tasks performed in an iterative way via machining simulations. The maximum utilization of five-axis machine tools depends upon the cutting system’s geometry, the configuration of the machine tool, and the workpiece’s location. In this research, a mathematical model has been developed to determine the workpiece’s feasible location in the five-axis machine tool for avoiding the number of iterations, which are usually performed to eliminate the global collision and axis limit errors. In this research, a generic arrangement of the five-axis machine tool has been selected. The mathematical model of post-processor has been developed by using kinematic modeling methods. The machine tool envelopes have been determined using the post-processor and axial limit. The tooltip reachable workspace is determined by incorporating the post-processor, optimal cutting system length, and machining envelope, thereby further developing an algorithm to determine the feasible workpiece setup parameters accurately. The algorithm’s application has been demonstrated using an example. Finally, the algorithm is validated for feasible workpiece setup parameters in a virtual environment. This research is highly applicable in the industry to eliminate the number of iterations performed for the suitable workpiece setup parameters.
Keywords workpiece setup parameter      five-axis      space utilization      setup parameters      machine tool     
Corresponding Author(s): Muhammad WASIF   
Just Accepted Date: 30 January 2021   Online First Date: 17 March 2021    Issue Date: 15 June 2021
 Cite this article:   
Aqeel AHMED,Muhammad WASIF,Anis FATIMA, et al. Determination of the feasible setup parameters of a workpiece to maximize the utilization of a five-axis milling machine[J]. Front. Mech. Eng., 2021, 16(2): 298-314.
 URL:  
https://academic.hep.com.cn/fme/EN/10.1007/s11465-020-0621-3
https://academic.hep.com.cn/fme/EN/Y2021/V16/I2/298
Fig.1  Difference between the current and the proposed methodologies for the feasible workpiece location.
Fig.2  Configuration of five-axis machine tool of Type III: (a) Actual HSM 600-C five-axis machine tools; (b) illustration of the axis configuration in Type III machine tool.
Fig.3  Relation between the part and the table reference system.
Fig.4  Relation between the table, the pivot, and the cutting system coordinate system.
Fig.5  Rotation of the b and c axes to coincide cutter orientation vector I with the xz plane of the part coordinate system: (a) Rotation of the spindle head about the positive b-axis, (b) vector I is in the+x and+y planes, (c) vector I is in the –x and+y planes, (d) vector I is in the –x and –y planes, and (e) vector I is in the+x and –y planes.
Fig.6  Rotation of the b and c axes to coincide cutter orientation vector I with the xz plane of the part coordinate system: (a) Negative rotation of the spindle head about the b-axis, (b) vector I is in the+x and+y planes, (c) vector I is in the –x and+y planes, (d) vector I is in the –x and –y planes, and (e) vector I is in the+x and –y planes.
Fig.7  Illustrations of the z- and b-axis ranges along with the tooltip reachable plan.
Fig.8  Table travel limits in the pivot point coordinate system.
Fig.9  Design part and rough stock. (a) Dimensions of rough stock; (b) faces in the designed part. Unit: mm.
Machining operation m Description Tool path Angle B/(° ) Angle C/(° )
1 Face milling of the top surface (face 1) to reduce 10 mm of stock
No. of CL points= 24		 0 0
2 Face milling of face 2
No. of CL points= 10		 –45 90
3 Face milling of face 3
No. of CL points= 8		 –45 180
4 Face milling of face 4
No. of CL points= 10		 –45 270
5 Face milling of face 5
No. of CL points= 8		 –45 360
Tab.1  Machining operations performed on the rough stock to produce the designed part
Fig.10  Feasible region of the workpiece setup parameters for (a) machining operation 1, (b) machining operation 2, (c) machining operation 3, (d) machining operation 4, and (e) machining operation 5.
Fig.11  Final feasible region of the workpiece setup parameters for all the machining operations.
Machining operation dx/mm dy/mm dz/mm
Minimum Maximum Minimum Maximum Minimum Maximum
1 −500.0 500.0 −300.0 200.0 −98.4 731.6
2 −300.0 100.0 −201.6 778.4 −98.4 731.6
3 −201.6 778.4 −300.0 200.0 −98.4 731.6
4 −300.0 100.0 −888.4 101.6 −98.4 731.6
5 −978.4 1.6 −300.0 200.0 −98.4 731.6
Final −201.6 1.6 −201.6 101.6 −98.4 731.6
Tab.2  Range of workpiece setup parameters
Fig.12  Setup parameters for the workpiece (a) outside and (b) within the feasible range.
Fig.13  Application 1: Cutter orientation according to vector I along with the travel required along the x- and y-axis: (a) Workpiece setup outside the feasible range; (b) workpiece setup within the feasible range.
Fig.14  Application 2: Cutter orientation according to vector I along with the travel required along the x- and y-axis: (a) Workpiece setup outside the feasible range; (b) workpiece setup within the feasible range.
Fig.15  Tool path generated in the machining workbench in CATIA.
CL No. CLx CLy CLz B/(° ) C/(° )
1 8.75714 30.90911 –9.24281 64.81276 –17.72390
2 17.27131 30.90948 5.64569 56.62592 –14.52250
3 27.08553 30.90939 17.00051 40.56632 –5.55806
4 36.33986 30.90923 22.40115 19.27390 –21.35730
5 44.39944 30.90919 23.38709 14.04658 106.00780
6 54.56399 30.90921 20.66752 27.69624 146.49920
7 70.26608 30.90918 11.68881 33.29906 161.60210
8 85.96813 30.90922 3.43085 20.89785 165.74080
9 101.67025 30.90924 1.20940 9.030762 –49.39430
Tab.3  CL in the part coordinate system and machine rotations
Fig.16  Feasible regions for the nine CLs and the final feasible region (polygon) enclosed by points P1, P2, …, P6, and P1.
Points dx/mm dy/mm
P1 –212.6 218.9
P2 –62.4 267.0
P3 99.2 284.0
P4 22.9 –98.1
P5 55.8 –298.0
P6 –42.5 –317.0
Tab.4  Coordinates of the feasible region
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