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Productivity enhancement for five axis free-form surface
machining using improved NC-program Simulation and augmented
steering functions

ProSi  aims at improving the preparation stage of free-form surface machining. The goal is to simulate a CNC program as close to reality as possible and to catch occuring surface errors and machining inefficiencies already in the simulation stage. This allows to speed up preparation time, and can help to enhance the quality of the surface and to mimimise postprocessing.

Nowadays, the machining preparation for machines with five axis is often split into multiple steps, as current tools do not support the complexity of three-dimensional programming sufficiently. Especially in the field of collision and singularity detection, region partitioning and optimal usage of the working volume, today's tools lack.

The overall simulation chain is shown on the picture. The results of every step will be taken into the visualization to show differences between each step in the processing chain, to depict problematic zones on the workpiece as well as in the control of the machine.

The current objectives are:
Enhancement of the planning reliability in the preparation stage
Optimal usage of machine stiffness for a gain in quality
Improvement of the machining quality using adjustment data from the simulation runs
Acceleration of the overall machining speed using a speed optimized NC program
Machine-adapted creation of a testing workpiece to validate the simulation chain and the project's concepts

The HLRS will contribute to this project with its knowledge in the field of technical visualisation. This will help in determining the success of the elaborated concepts using three dimensional representations of the work pieces as well as the machine-tools, augmented with additional information such as tool speed, deviations, forces and other.

Main partners at the University of Stuttgart are the ISW and IfW, at the University of Karlsruhe the WBK and as external research facility the ZFS.

The ProSi project ran from 2002 - 2005

For more information, please contact Andreas Kopecki