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Procedia CIRP 1 (2012) 102 107

5th CIRP Conference on High Performance Cutting 2012

Advanced method of NC programming for 5-axis machining

Sergej N. Grigorieva, A.A. Kutinb, V.V.Pirogovc*
a
Department of High-effective Machining Technologies, State Technological University STANKIN, Vadkovsky per. 1, Moscow 127994, Russia
b
Department of Manufacturing Engineering, State Technological University STANKIN, Vadkovsky per. 1, Moscow 127994, Russia
c
Department of Manufacturing Engineering, State Technological University STANKIN, Vadkovsky per. 1, Moscow 127994, Russia
* Corresponding author. Tel.: +7-499-972-9449 ; fax: .E-mail address: [email protected] .

Abstract

This paper presents a method to simultaneously increase the accuracy and decrease the calculation time for complex tool path
programming in multi-axis machining centers. Examples of complex parts requiring such complex tool paths include various kinds
of turbine blades, pump-forcing augers, teeth surfaces, etc. It explains the creation of topological structures on the basis of
analytical spline curves with floating range definitions. The method for tool path calculation accommodates the specific
requirements for multi-axis milling. The algorithms developed are the foundation for the CAD/CAM software that allows for NC
programming and machining on 5-axis centers employing any design model. Industrial tests reveal a 70-80% reduction of NC
programming time of parts with complex surfaces, reduced machining time of approximately 40-50% using basic high-speed
cutting methods and custom-made tools. The advanced methods of NC programming result in substantially increasing machining
accuracy.

2012
2012 The
Published byPublished
Authors. Elsevier BV. Selection
by Elsevier B.V.and/or peer-review
Selection under responsibility
and/or peer-review of Prof. Konrad
under responsibility Wegener
of Professor Konrad Wegener
Open access under CC BY-NC-ND license.
Keywords: NC programming, multi-axis milling, CAD/CAM software, machining accuracy

1. Introduction the new design 6 hours and 20 minutes is required. This

is caused by:
Recently, computer capabilities have substantially using the tool of smaller diameter reduced the feed
increased the programming speeds which in turn enabled rate from 200 mm/min to 80 mm/min;
a 90% reduction of machining time for components the introduction of additional operations because of
using a variety of methods [1, 2]. However, reduction of blade thickness resulted in a high level
implementing high speed and multi-axis machining in of material removal, resulting in increased part
manufacturing requires new software for complex deformations.
surfaces. At the same time, developers continuously For machining time reduction, high-speed cutting and
improve and develop more elaborate products that cause new technological methods of multi-axis milling are
additional difficulties in manufacturing. These problems required. This has required the development of new
cannot be solved by using today's mainstream methods of NC programming to increase accuracy and
algorithms. As an example, consider a turbine wheel speed of tool path calculation.
with blades of double curvature (fig 1). In order to
increase the exerted force of the wheel, designers have
doubled the number of full and truncated blades. Thus
blade thickness has decreased. Real machining time of
such a wheel should be doubled, but actually time of
manufacturing has increased almost 10 times. Previously
the machining time of one channel took 1 hour, but with

2212-8271 2012 The Authors. Published by Elsevier B.V. Selection and/or peer-review under responsibility of Professor Konrad Wegener
Open access under CC BY-NC-ND license. http://dx.doi.org/10.1016/j.procir.2012.04.016
 Sergej N. Grigoriev et al. / Procedia CIRP 1 (2012) 102 107 103

choice of value of number N:

N = max(nx , n y , n z )
(4)

Proceeding from the accepted equations (2) and (3),

the general computing structure can be written:

N
C (t ) = 1 ac0 + (ack cos(k 2 t ) + bck sin(k 2 t ))
2 k =1 T T
Fig. 1. Turbine wheel with changed blades , (5)

where N = max(nx , n y , nz ) .
2. Use of topological structures for the creation of
mathematical models for 5-axis machining Having generated matrixes of factors as vectors of N -
measurement and having made the amendment which
Increase of accuracy and geometrical complexity of makes 1/2, inside of a vector aco, can be determined:
modern products demands further development of

software for 5-axis programming of CAM systems. Ac = (ac1, ac2 ,, acN )

Calculations show that for an increase in the accuracy of Bc = (bc1, bc2 ,, bcN )

approximation 10 times, the calculation time increases 1 1 1

ac = ( a x0 , a y0 ,, a z0 )
100 times. Because these problems arise during tool path 2 2 2
(6)
modeling, permanent model recalculation is necessary
and time for such recalculation is very long. For a settlement part vectors of N-1 - measurement
The generalized equations for definition of a curve as cosine and sine:
an analytical spline are [3]:

= (cos( 2 t ), cos( 4 t ),, cos( N 2 t )

1 nx 2 t ) + b sin(k 2 t )) T T T
x(t ) = a x0 + (a xk cos(k

xk
2 k =1 T T S = (sin( 2 t ), sin( 4 t ),, sin( N 2 t )

ny T T T (7)
C (t ) = y(t ) = 1 a y0 + (a yk cos(k 2 t ) + b yk sin(k 2 t ))
2 k =1 T T

n From (6) and (7) the common mathematical structure
z
(a zk cos(k 2 t ) + bzk sin(k 2 t ))

z(t ) = 1 a + of calculations can be obtained:

2 z0 k =1 T T
(1)
C(t) = ac + ( Ac Cc ) + (Bc Sc ) (8)
Consider (1) from the point of view of algorithmic
maintenance of functions of a mathematical model. Having determined (8) as the mathematical basis for
Having obtained the general computing method for all calculation of geometrical parameters of curves on all
kinds of curves, matrix products are the most convenient part models, is possible to include all settlement
way for the settlement base of the software. The sets of algorithms on all elements in a parallel mode. Forming
factors, namely a vector factors a (2) and a vector of vector matrixes Cc and Sc, and further, using their scalar
factors b (3) can be determined as: multiplication with vector matrixes Ac and Bc and
amending on a vector a c it is possible to calculate all
ac0 = (a x0 , a y0 , a z0 )
edges inside a cycle and on all cycles simultaneously.

ac1 = (a x1, a y1, a z1) Such a mode of calculations allows a reduction number

 of repeated operations to the least amount of the same

acN = (a xN , a yN , a zN ) edges in part model. As a result the real gain in time of
(2) calculation will be approximately 80 per cent. It enables
the process of preparation of computing structures Ac
bc0 = (0,0,0)
and Bc for the curves. Representation for a surface based
bc1 = (bx1, b y1,bz1)
on u and v curves can be presented as follows:
(3)


bcN = (bxN , b yN ,bzN )

Logically to apply a rule of the maximum factor for

104 Sergej N. Grigoriev et al. / Procedia CIRP 1 (2012) 102 107

1 n documentation and models resulting from design

x(u, v) = 2 (a x0 + v(c x0 a x0 )) + k=1((a xk + v(c xk a xk )) process. This kind of initial information is the basic for
machining modeling.
cos(k 2 u) + (b + v(d b )) sin(k 2 u) The identification of similar tasks is realized in the
xk xk xk
T T
special program modules executed together with
1 n
y(u, v) = (a y0 + v(c y0 a y0 )) + ((a yk + v(c yk a yk )) program complex T-Flex CAD/CAM 10.0 [4, 5].
2 k =1 For demonstration of parameters and the operations
S (u, v) =
cos(k 2 u) + (b + v(d b )) sin(k 2 u) which are carried out by these modules consider an
yk yk yk example of NC programming for parts with spatially
T T
1 n complex surfaces (SS).
z(u, v) = (a z0 + v(c z0 a z0 )) + ((a zk + v(c zk a zk )) The spatial complexity of surfaces of considered parts
2 k =1
is determined by the following features (fig. 2):
2 2
cos(k u) + (bzk + v(d zk bzk )) sin(k u)
T T
(9)

where

T T

2 2 2 2 2 2
axk = xl ( )cos(k )d ; bxk = xl ( )sin(k )d
T T T T T T

2 2 , k 0;nx

T T

2 2 2 2 2 2
cxk = xr ( )cos(k )d ; dxk = xr ( )sin(k )d
T T T T T T

2 2

3. Creation of topological model of surfaces

association for tool path calculation
Fig. 2. Example of spatial complexity of surfaces

The created model of tool path calculation is focused

on 5axis milling with an opportunity of the 1. Geometrical complexity. Parts will consist of
parametrical issue of technological parameters. The surfaces of double curvature and smooth interfaces
share of five-axis milling among other kinds of metal specified by the hydrodynamic or aerodynamic
machining increases every year. However, alongside analysis of parts specifications. This does not
with requirements of machining for one set up without allow tool path calculations on a basis of linear
change of technological bases, there are also a number of transitions on the similar contours. It is necessary
essentially new problems. All these problems can be to take into account coordinates of each point on a
divided on three basic groups: surface and the directions of normal to them for
obtaining the maximal machining speed and the exact calculation of coordinates of the position
reduction in machining time; and inclination of the tool. It is also necessary to
reduction the number of technological operations due take into account continuity up to the second
to the increase of accuracy of the intermediate stages derivative at least, in order to be able to analyze
of machining; the change of curvature from one set point to the
increasing machining accuracy of a product to meet other.
customers. 2. Technological complexity. Some parts have a
All these tendencies should to be taken into account relative positioning of surfaces that is resulting in
adequately during process planning. Thus, the the formation of "shadow zones and narrowing.
CAD/CAM system within which NC programs are being The technological effect of cutting tool sliding
created, should describe precisely part geometry, have from the surface can also result in the surface
flexibility for the task of relative position of the tool and being cut off. In this case it is necessary to set
workpiece and also be able to take into account features position of the tool to exclude the contact of
of cutting process. Thus, in the system structure should peripheral part of the tool with other surfaces.
be taken of features governing all electronic 3. Joint geometrical and technological complexity
which is a ratio of the geometrical sizes of a part
 Sergej N. Grigoriev et al. / Procedia CIRP 1 (2012) 102 107 105

elements (for example, the height and thickness of 4. Calculation of the cutting tool path in five-axis
blades), and also a transition point of base forming milling
surfaces result in a non-uniform distribution of
rigidity along all machining surfaces. Various It is possible to attribute various parametrical ways to
sizes of the pliability of a part do not allow cutting set off an advancing angle, parametric item milling and
force to be constant which in turn makes it parametric definition of an allowance to the features of
impossible to achieve constant technological 5-axis milling. True part geometry influences the correct
parameters such as cutting depth, feeds etc. This calculation of the cutting tool position. For correct
makes it necessary to provide continually variable adjustment of the equipment during five-axis machining,
technological parameters during NC programming. NC programs are usually positioned on the center line of
the cutting tool.
The T-Flex CAD/CAM system includes specialized However, while manufacturing on machine tools, the
algorithms, which allow taking into account these surfaces quality depends on cutting parameters, and also
features. from angular position of the tool. This gives the highest
The preliminary stages of parametrical processing are importance to a method for dealing with corners and also
the functions which carry out calculation of the base of their definition concerning the current area of
areas of definitions of each surface forming tool path. movement of the tool. One more question at the design
For use of this algorithm it is necessary to make a 3D of algorithms is that the angles of an advancing tool,
contour on the basis of limiting sides, and then to which are dependent on the machine-tool. For the
proceed to the task of geometrical parameters for NC calculation of advancing angles in T-Flex CAD/CAM
programming. Consistent choice of a part model and system there are some opportunities of definition of the
specifying it, directing the 3D path of the top contour inclination of the tool:
and limiting the 3D path of the bottom contour enables 1. Advancing angles are set as an inclination
the definition of a geometrical component of tool path. lengthways and perpendicularly to a direction of
The further steps of calculation are the following: movement;
the surfaces limited to chosen ways, by software 2. The inclination of the tool is set by a focusing
combined in a uniform surface; method;
equidistance is designed to a surface and 3. Advancing angles are as dual equidistance.
displacement is determined by the radius of the tool; In this case the axis of the tool passes through
depending on type of the chosen passes, it is possible corresponding points on two spatial curves (fig. 3).
to obtain a set of closed coils of a tool path in which
each point goes from a constant component on V =
const: "loop" or "zigzag", or on a coil, where each
point will go with a constant depth and a component
on V = V+dV, which is a spiral line with constant
step of depth (where V stands for isoparametrical
line).
This not only obtain a cutting tool path with precisely
certain position, but also takes into account the form of
the limiting contours which set the form of passes. It
allows at a part manufacturing stage to take into account
its functional features.
The advantages of this method of defining cutting
tool movement when machining a spiral trajectory are as
follows:
1. Continuous and constant material removal.
2. Machining time is determined by cutting process. Fig. 3. An example of designing a focusing curve tool path.
Auxiliary transitions from one height on another are
excluded and there is no necessity to updating of
surfaces interfacing the basic geometrical elements. The first curve is a movement of the center of the tool
sphere. The second curve is a spatial line received by
transformation of the first curve to the following
sequence. Vector 1 determines equidistant shift of a line
in a direction of a normal to the initial surface. Vector 2
sets the size of rise of the shifted path, relative to the flat
106 Sergej N. Grigoriev et al. / Procedia CIRP 1 (2012) 102 107

side of the part. Thus the obtained second curve is

similar to the first, and the inclination of the tool takes
into account the direction of a normal at a point of
contact of the tool and the model.
Such an approach allows setting of a constant angle
of the tool inclination to a machined surface in a
direction perpendicular to tool movement, instead of
starting position of the tool on a path that distinguishes
this way from traditional approach.

5. Position milling

Machining is conducted on the five-axis equipment

with the fixed angular coordinates due to linear
movement. The module 5D-zoned Milling of
CAD/CAM T-Flex system supports simultaneous use of
position and five-axis machining during tool path
calculation.
In a dialogue mode it is possible to set ranges and
values of change of advancing angles. The range is Fig. 4. An example of a five-axis milling
determined parametrically as an interval of length of the
first chosen path. Scanner consists of dental 3D-camera, a 3D-camera
In case of ventilating wheels machining the following holder and 3-coordinate table with 2 linear coordinates
characteristic zones (fig. 4) has been established: and 1 angular coordinate. The dental model is located on
1. Lateral blade surfaces - three-axis milling with a coordinate table. Moving of a dental model allows
fixed in-angle coordinates (3D+2D); registering and reconstructing of its separate parts. Then
2. Rounding surfaces five-axis milling (5D). separate reconstructed surfaces of the dental model are
From the technological point of view the optimal unified by the software.
machining is coordinate 3D milling and forming of Dental CAD/CAM system includes the following
spiral path by 5-axis machining. units:
During tool path calculation there is an opportunity to Scanner;
decrease the influence of machine tool dynamic Software for working with scanner and restoration
components on product quality. modeling;
This is achieved by the ability to smoothly vary the NC milling machine, (fig.5);
feed rate in all coordinates and by elimination of sharp Software for working with the NC milling machine.
path trajectories, which is especially important for
machining of thin wall structures.

6. Examples using of the developed methods in dental

CAD/CAM systems

Last years fast rates began to be developed in dental

practice CAD/CAM systems for modeling the teeth and
their manufacturing on multi-axis CNC desktop machine
tools.
3D-Software is used to model restoration.
The dental CAD/CAM-system includes the scanner.
The scanner is opto-mechanical device for non-contact
optical measurement of dental model surface.

Fig. 5. Work area of the dental CNC milling machine

The main characteristics of such a system are:

 Sergej N. Grigoriev et al. / Procedia CIRP 1 (2012) 102 107 107

Surface measurement accuracy 25 m;

Restoration manufacturing 40 m;
NC programming time is 10 minutes.
Time of restoration manufacturing is less than 30
minutes.
Size of CNC milling machine 490460370 mm;
Weight of CNC milling machine is less than 50 kg.

7. Summary

Working with specialized CAM modules a minimum

quantity of geometrical elements is necessary for a
choice of machining strategy, which is impossible to
carry out, using the standard approach of modeling in
CAM-system. It allows more than half NC programming
time reduction for machining of components with
complex surfaces, due to improved tool path calculation
capacity.
For maintaining geometrical accuracy of machined
parts, the process of tool path calculation is necessary in
order to obtain a continuous model with the use
equidistant surfaces that allows increasing accuracy of
machining.
In the CAM-system the basic criterion of
technological flexibility is the opportunity for tool
orientation depending on technological features of
machined part. Thus it is possible to use all of the
advantages of five-axis machining on CNC machine
tools.
Maintenance of the set of machining accuracy and
minimization of defective products is solved at two
stages of the path calculations removal of trajectories
in the middle of an admission field and the account of a
variable pliability of a detail in two directions.

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