Tool path generation for 4-axis contour EDM rough machining

Ding, S and Jiang, R 2004, 'Tool path generation for 4-axis contour EDM rough machining', International Journal of Machine Tools and Manufacture, vol. 44, no. 14, pp. 1493-1502.

Document type: Journal Article
Collection: Journal Articles

Title Tool path generation for 4-axis contour EDM rough machining
Author(s) Ding, S
Jiang, R
Year 2004
Journal name International Journal of Machine Tools and Manufacture
Volume number 44
Issue number 14
Start page 1493
End page 1502
Total pages 10
Publisher Elsevier Inc.
Abstract Contour or CNC EDM machining of free-form surfaces requires tool paths that are different from those used in mechanical milling although in geometry both processes are described by the similar model of intersection between the rotating tool and the workpiece. In this paper, special requirements on tool paths demanded by contour EDM machining are studied and a two-phase tool path generation method for 4-axis contour EDM rough milling with a cylindrical electrode is developed. In the first phase of the method, initial tool paths for virtual 3-axis milling are generated in a commercial CAD/CAM system - Unigraphics, which provides users with plenty of options in choosing suitable tool path patterns. From these tool paths, cutter contact (CC) points between electrode and workpiece are reversely calculated. In the second phase, considering the special requirements of EDM machining, which include discharging gap compensation, electrode wear compensation, DC arcing prevention, etc., the electrode is adjusted to an optimized interference-free orientation by rotating it around the CC points obtained in the previous phase. This new orientation together with the reference point of electrode is output as new tool path. The whole algorithm has been integrated into Unigraphics, machining simulations and tests have been conducted for 4-axis contour EDM rough machining.
DOI - identifier 10.1016/j.ijmachtools.2004.05.010
ISSN 0890-6955
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