Surface roughness parameters determination model in machining with the use of design and visualization technologies

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1 Surface roughness parameters determination model in machining with the use of design and visualization technologies N. Bilalis & M. Petousis Technical University of Crete, Chania, Greece A. Antoniadis Technological Educational Institute of Crete, Chania, Greece ABSTRACT: A virtual reality machine shop environment was developed for the determination of critical quantitative and qualitative machining process parameters. Material removal and milling machine axes kinematics are simulated in real time. The G-Code program serves as the input to the system. A graphical model for the calculation of quantitative data affecting the machined surface roughness was developed. In the model, the machined surface topomorphy is derived as a cloud of points, retrieved from the visualization system Z buffer. The current study is focused on the verification of the quantitative data acquired by the system. A numerical model experimentally verified in the past was integrated to the system to directly evaluate results accuracy. The model accuracy was also verified with results determined in cutting experiments. The calculated surface roughness values were found to be in agreement with the values determined from the numerical model and the experiments. 1 INTRODUCTION Currently a lot of progress has been made on the application of Virtual Reality tools in various stages of product development. Aim of this work is the integration of virtual environments with production design processes. A production processes simulation system was developed for the determination of critical quantitative and qualitative process parameters. The system provides realistic visualization of the process in a three dimensional virtual machine shop environment with walk/fly through and interaction capabilities. System user acquires information related to the process being simulated in the virtual environment in real time. The system extends CAM systems capabilities, by intergrading CAM system functionalities with quantitative data determination models in a three dimensional virtual environment. The system could be used for the verification of machining processes and as an educational tool, because of the realistic graphics environment in which the machining processes are being simulated. The current study is focused on the verification of the quantitative data acquired by the system. 2 LITERATURE REVIEW In this section systems similar to the presented are described, that is systems for machining processes simulation in virtual environments with surface roughness quantitative data determination capabilities and models based on graphics technology for machining operations quantitative data determination. Antoniadis et al. (2003) presented a model for surface roughness determination. In this model the workpiece is being modelled with vertical linear segments. As the cutter moves along the machining process trajectory, linear segments decrease their height to the lowest intersection position with the cutter edges. At the end of the simulation, needles vertices define the final machined surface. The model was experimentally verified and the calculated roughness levels were found to be in agreement with the experimental ones. Iowa University (1994) developed a system for machining processes simulation in a five axes CNC machine. The system aims at the improvement of the workpiece machined surface quality by improving the cutter path. Ko et. al. (2003) developed a Virtual Manufacturing system for the determination of optimum feedrate values in 2.5 machining processes that provides the ability to determine cutting forces in order to improve the machined surface quality. Qui et al. (2001, 2002) presented a Virtual Reality system for material removal simulation that provides information about the required time for the completion of the machining process and quantitative data like cutting forces, surface roughness, required energy and cutter wear. Bath University (1996) developed a simulation system for several types of machining operations that could be employed for design, modeling and imple-

2 mentation of production plans in the virtual environment, aiming at errors detection in the executed operations. Kim et al. (2000) presented a cutting forces determination model for milling processes of sculptured surfaces with ball-end cutters. In order to determine chip thickness from the intersection area between the cutter and the workpiece, a graphical method based on the Z-map was developed. Roth et al. (2003) presented a cutting forces determination model for milling processes in multi axis machines. The model is based on the Z buffer and exploits the system graphics card. 3 VIRTUAL ENVIRONMENT FOR MACHINING PROCESSES SIMULATION During machining process simulation, CNC machine axes and cutter animate in a realistic way. Workpiece material removal is being visualized in a realistic way during machining process simulation. Machining process information like the G code command simulated in the CNC machine, feed, spindle speed and cutter path are being visualized in a special table. User can pause, stop or restart the machining process. When the machining process is completed, quantitative data and graph charts related to the machined surface roughness are being visualized, according to user preferences. A virtual environment was developed using commercial software tools for the realistic visualization of machining processes. The structure of the virtual environment is shown in Figure 1. A complete machine shop is being visualized and the functional characteristics of a three axes CNC milling machine are being simulated. In Figure 2 the virtual environment for machining processes simulation is presented. The virtual environment has the following functional characteristics: Objects behavior is as realistic as possible. User has the ability to interact with all the objects in the virtual environment. User selects cutter from the cutters table and it is installed automatically in the CNC machine spindle. User selects workpiece from the workpiece table and it is installed automatically in the CNC machine worktable. 4 VIRTUAL ENVIRONMENT SOFTWARE MODULES The following modules of the environment were developed and integrated in the employed Virtual Reality platform for the implementation of the machining processes simulation environment: Geometrical models visualization: Models developed in CAD like the machine shop environment and the machines, dynamic geometry models like the workpiece, 3D text and graphs, virtual models visualization characteristics, like color and texture. Geometry models hierarchy, constraints, interaction attributes. CAM system integration. Cutter path determination according to the G code program. CNC machine axes and cutter animation. Workpiece material removal visualization during machining processes simulation. Figure 1. Structure of the virtual environment for machining processes simulation Figure 2. Virtual Environment for machining processes simulation

3 Quantitative data determination. Verification checks during machining processes simulation. The current study focuses on the quantitative data capabilities of the system and the process for their verification. 5 QUANTITATIVE DATA DETERMINATION A model was developed for surface roughness quantitative data determination. In the model, parameters such as the cutting speed, feed, cutting depth, cutter diameter, height, cutter type, number of teeth and cutting edges geometry that contribute in surface roughness formation are considered. Parameters that contribute in surface roughness formation, such as the cutter material, quality and type of the cutter, cutter wear, quality of jigs, fixtures, the use of lubricant, vibrations in the machining process are not considered. 5.1 Determination of machined surface topomorphy The model for the determination of the machined surface topomorphy was implemented in a three dimensional graphics environment developed in OpenGL (Fig. 3). The simulated motion of the cutter and the cutting conditions are obtained directly from the G code file. The sweep surface produced by the cutting edges is being determined. Cutting edges shape is defined from the outer edge profile of each cutting edge (Fig. 4). Each cutting edge is approximated by equal elementary sections that are straight lines (Fig. 5). The produced sweep surface from each cutting edge is approximated by triangles. Therefore there are overlapping triangles, since part of each cutting edge sweep is being overlapped by the next cutting edge sweep or the next cutter pass sweep. If the cutter sweep surface is projected from its down side, the final machined surface topomorphy is derived, since the overlapped triangles are not visible in this projection, due to the hidden line algorithm, that projects to the user only the geometry visible in each point of view. This final machined surface topomorphy is derived from this projection in the form of cloud of points. The coordinates for the cloud of points are determined. The pixels within workpiece limits visualize the machined surface. These pixels are converted into X and Y coordinates in the graphics environment coordinate system. Z coordinate is derived from the visualization system Z buffer. The coordinates for the cloud of points describing the machined surface topomorphy is exported in a text file and used to calculate quantitative parameters for the machined surface roughness in the virtual environment. 5.2 Calculation and visualization of surface roughness parameters in a virtual environment A table was developed for surface roughness quantitative data visualization (Fig. 6). On the upper part of the table the measurement plane on the workpiece machined surface is defined. On the lower part of the table the selected measurement plane topomorphy and the respective surface roughness parameters values are being visualized. For the determination of the measurement plane, a handler was developed (Fig. 7). The handler defines a plane vertical to the machined surface in which topomorphy will be determined and surface roughness parameters will be calculated from this topomorphy. System user defines the position of each handler end. Handler ends define surface roughness measurement plane limits. For surface roughness parameters determination, cloud points near the vertical measurement plane are retrieved from the file. The user has the ability to create a machining process report in the form of a text file (Fig. 8). In the machining process report file, surface roughness data for a region around the measurement plane are being stored and can be acquired for further use. This process can be repeated in any other region of the machined surface. 6 MODEL VERIFICATION In this section the process for the verification of the developed surface roughness quantitative data determination model is described. The process is shown in Figure 9. The results acquired by the model were verified with the experimentally verified machining simulation numerical model MSN (Milling Simulation by Needles), which was integrated in the OpenGL software in order to provide direct control on model results, when implementing experiments is not possible. Moreover, quantitatively and qualitatively model results were verified with experimental data. 6.1 Verification of the machined surface topomorphy with the MSN model The accuracy of the developed model for machined surface topomorphy determination is influenced by the following parameters: Cutter model discretization density. Cutter trajectory discretization density. Hidden lines algorithm employed by the system.

4 (a) Edge on a ball (b) Six cutting edges ball end mill end mill Figure 4. Cutter cutting edges modeling Figure 5. Ball end mill cutting edge modeling Figure 3. OpenGL machining processes simulation environment for machined surface topomorphy determination Figure 6. Virtual environment quantitative data table Figure 8. Machining Report example Figure 7. Measurement area determination with the use of the handler Figure 9. Quantitative data determination model verification process Projection type used for three dimensional graphics visualization. Orthographic and perspective projection is supported. Orthographic projection is used, because in perspective projection objects are deformed to create the sense of depth to the user and errors can arise due to the deformed visualization. Position and angle for the projection of the cutter sweep surface from its down side, in order to determine the machined surface. Z buffer accuracy is influenced by these parameters. The MSN milling simulation model is being executed simultaneously with the model developed in the current study. The final machined surface is being determined with two different clouds of points, from the MSN model and from the Z buffer values for the pixels within workpiece limits representing the lowest cutter sweep surface. Since both models are being executed simultaneously during the machining process simulation, the two clouds of points are formed with the same cutting conditions. In the first verification stage of the model, the two clouds of points are compared. The comparison aims at the determination of the Z buffer accuracy with respect to a mathematical method. Due to different workpiece discretization in the two models, Z coordinates are compared for vertices and pixels respectively having similar X and Y coordinates. The accuracy of this comparison method depends on the discretization step in the clouds of points, since, as the density of the cloud increases, the compared points are closer and the accuracy of the comparison is higher. A difference in the Z coordinate is expected since the compared points are not in the exact same position.

5 Moreover, the accuracy of the cutter sweep surface is verified. For this verification, a surface is defined from the data obtained from the MSN model. This surface is stored with the same method as the cutter sweep surface, that is a cloud of points produced using the Z buffer. This cloud of points is compared with the cutter sweep surface cloud of points by directly comparing the Z coordinate of every pixel. Since both clouds of points in this verification are being produced with the same method and at the exact same position and zoom level, the difference between them shows the level of accuracy of the machined surface determined with the current study model. Both verifications are performed by a software tool. The average deviation between the needles cloud and the cutter sweep surface cloud was 3%. The average deviation between the surface produced with the MSN model and the cutter sweep surface cloud was 0.05%. In Figure 10, for the same machining operation, surface topomorphy defined by the MSN model and by the Z buffer is shown in isosurface mode with colour scale, to facilitate evaluation. (a) Needles vertices 6.2 Verification with experimental data Surface roughness quantitative data acquired from the system were compared with experimental results to directly verify the developed model. In the cutting case described in this section a part and its production process were designed in a CAD/CAM system. The part was manufactured with a ball-end tool with one cutting edge and different cutting conditions. The G code file used for the part manufacture was imported in the virtual environment for the simulation of the process, in order to ensure that the real and the virtual experiment have identical cutting parameters. The part developed for the cutting case is shown in Figure 11. The machining process simulation for the construction of the part geometry in the virtual environment is shown in Figure 12. Roughness measurements were taken inside the pocket geometry, which was machined four times with different cutting conditions (up/down milling, change of feed, step over and depth of cut). To construct the pocket geometry, a circular trajectory was followed in all cases (Fig. 13). The number of passes is determined according to the step over parameter value, defined in the cutting conditions. Roughness measurements were taken along the circular trajectory, vertically to the feed direction, for the four different cutting conditions. Four roughness measurement areas were selected in different trajectory positions. In each area measurements were taken in measurement planes with length 5mm (Fig. 13). In Figure 14 the results from the virtual environment are correlated with experimental results. In the virtual environment figures, the measurement plane and length are also shown. Results from the virtual environment and the experiment are in good agreement, considering that some parameters affecting surface roughness are not taken into account in the developed model. Figure 11. Experiments part geometry Figure 12. Machining simulation in the virtual environment (b) Z buffer Down milling, sz=0.2mm/rev,edge, txy=0.3mm, tz=0.3mm, Ball End D20, z=1, P02 (TiN), Ck60 Figure 10. Machined surface topomorphy

6 7 CONCLUSIONS Figure 13. Pocket milling trajectory and measurement planes Virtual Environment Experiment Ra = 0.71 Rz = 4.82 Rt = 5.99 Up milling, sz=0.2mm/rev,edge, txy=0.3mm, tz=0.6mm Ra = 0.66 Rz = 3.98 Rt = 5.74 Currently there is a tendency for Virtual Reality characteristics and production processes models integration. This tendency is leading to the creation of the next generation simulation systems that will provide quantitative data for the process, increased visualization, fly through and interaction capabilities in a virtual environment. The presented system extends CAM system capabilities, since it provides higher level visualization functionalities and quantitative data for the production process defined in the CAM system. A new method based in OpenGL programming language is presented for machined surface topomorphy determination in order to calculate critical quantitative data affecting machined surface roughness. The surface roughness quantitative data verification method followed showed that the results acquired by the system are in agreement with both the numerical model and the experimental results, making the model suitable for integration in production design processes. The system could be extended to other types of machining operations or production processes in order to provide an integrated virtual machine shop environment for production processes simulation. ACKNOWLEDGMENT The project is co-funded by the European Social Fund and National Resources EPEAEK II IRAKLITOS Up milling, sz=0.6mm/rev,edge, txy=0.3mm, tz=0.3mm Ra = 0.38 Rz = 1.93 Rt = 2.19 Down milling, sz=0.2mm/rev,edge, txy=0.3mm, tz=0.6mm Ra = 0.42 Rz = 2.57 Rt = 3.95 Down milling, sz=0.2mm/rev,edge, txy=0.4mm, tz=0.3mm Ball End D20, z=1, P02 (TiN), Ck60 Figure 14. Comparison between virtual environment and experimental results REFERENCES Antoniadis, Savakis, Bilalis, Balouksis Prediction of surface topomorphy and roughness in ball end milling, Advanced Manufacturing Technology 21: Bowyer, Bayliss, Taylor, and Willis A virtual factory, International Journal of shape modeling, 2(4): Kim, Cho Chu Cutting force prediction of sculptured surface ball-end milling using Z-map, Machine Tools and Manufacture 40(2): Ko, Yun, Cho Off-line feed rate scheduling using virtual CNC based on an evaluation of cutting performance, CAD 35: Qui, Chen, Zhou, Ong, Nee An Internet Based Virtual CNC Milling System, Advanced Manufacturing Technology 20: Roth, Ismail, Bedi Mechanistic modeling of the milling process using an adaptive depth buffer, CAD 35(14): Qui, Chen, Zhou, Ong, Nee Multi User NC Machining Simulation over the Web, Advanced Manufacturing Technology 18: 1-6. Huang, Oliver NC milling error assessment and tool path correction, International Conference on Computer Graphics and Interactive Techniques, Proceedings of the 21st annual conference on Computer graphics and interactive techniques

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