Five-axis Machining The Sweep Contour Calculation Expression And Software Implementation

5-axis numerical control (NC) machining technology is widely used in aviation, automobile, marine and modern mould industry, etc. It is irreplaceable in high precision complicated curved surface machining. In domestic and foreign research, the important and difficult point is how to give full play of its high flexibility, high precision and high efficiency. This thesis performs systematic research on calculation and expression theory of swept profile in 5-axis machining, and applies the theory into project software design. The main content is as follows:1. Express the subject research background and importance This thesis introduces the present situation of 5-axis machining technology research and the development of 5-axis numerical control machining tool. It analyses several kinds of common swept surfaces and swept profiles to get the advantages and disadvantages. It also analyses the feasibility and limitation of current fillet-end cutter and its optimization.2. This thesis presents an explicit expression of the swept profile on fillet-end cutter for the spindle rotation type of 5-axis machining. It fully analyses the geometric shape and characterization of the swept profile on different parts of the cutter surface, and lists every possibility of the swept profile. The method is highly efficient and precise. It lays a mathematic foundation for dynamic simulation and machining error control in complicated curved surface manufacturing.3. This thesis presents an explicit expression of the swept profile on fillet–end cutter for a table rotation type of 5-axis machining. It analyses the geometric shape and characterization of the swept profile on cutter curved surface. The method is highly efficient and precise, and lays a mathematic foundation for dynamic simulation and machining error control in complicated curved surface manufacturing.4. This thesis presents algorithms of representing the cutter swept profile in 5-axis machining by a B-spline curve. First, the profile's second derivative is calculated by the explicitly expression, based on which the number of sampling points on swept profile is evaluated. Then the sampling points are interpolated by a B-spline curve, and further its unwanted knots are removed by using the approximation tolerance. From this, we get the B-spline curve. The algorithms can be extended to represent the cutter swept surface by a B-spline curve. Therefore it lays a foundation to further improve tool dynamic simulation, verification and machining error control of 5-axis machining.5. With the successful development of CAD/CAM software system for the fillet-end cutter mould based on Windows, this thesis presents the system working process and function models. It introduces the curve and surface modeling theory with C-Bézier, as well as the realization of main function models using MFC and OpenGL. This system design method and technology can be adopted in other professional CAD/CAM systems.