NC DATA PREPARATION FOR WORKING CURVED SURFACE

Abstract: A curved surface (101) has a cut boundary surface (102) in the direction of depth. Data for specifying a three-dimensional curved surface and a boundary curved surface of cutting in the direction of depth are inputted, and sequence of points Q (i,j) of the tip of a tool corresponding to sequence points A (i,j) is determined when the three-dimensional curved surface is defined by a set of a number of sequences of points (11i). Next, the projected sequence of points B' (i,j) formed by projecting the sequence of points Q (i,j) of the tip of the tool on a reference plane (103) is determined and the projected sequence of points C (i,j) formed by projecting that projected sequence of points on the boundary curved surface is determined. Whether the line connecting the points Q (i,j) of the tip of the tool crosses the line connecting the projected sequence of points C (i,j) on the boundary curved surface is checked and, if it does, the NC data up to the crossing point P (i,j) is prepared and the NC data are prepared in the same way by performing pick feeding.

Description: This invention relates to a method of creating NC data for machining curved surfaces. More particularly, the invention relates to a method of creating NC data for machining a curved surface having a cutting boundary surface in the depth direction. In the numerically controlled machining of a three-dimensional mold or the like, a curved surface is defined by a plurality of section curves, a point sequence is generated on the curved surface from data such as that indicative of the section curves, data relating to the generated point sequence on the curved surface are stored on an NC tape, and machining of the curved surface is executed by commands from the NC tape. When a curved surface is defined from data (section curve data) on a mold design drawing and the entire region of the generated curved surface is machined, there are cases where a neighboring surface is cut into or where, conversely, an excessively large vacant cutting path is generated, leading to waste in terms of machining. Consequently, a method has been developed for use when machining a curved surface 101, as shown in Fig. 6. The method includes designating a cutting boundary 105 in the depth direction in a plane 104 located at a height Z H from an X-Y plane, outputting a machining point sequence P i (i = 1, 2, ...) up to the cutting boundary, thereby creating NC data, and subsequently creating NC data in the same manner upon performing a pick-feed. It should be noted that whether the point sequence P i has reached the cutting boundary 105 is determined based on whether the Z coordinate of the point sequence P i has become less than Z H . When a curved surface 101′ is machined, as shown in Fig. 7, there are times when it is desired to prevent cut-in by adopting any curved surface 104′ as a cutting boundary surface in the cutting direction. For example, there are cases where a TV frame is cut on the curved surface of a cathode ray tube. In cases such as these, machining in accordance with the prior art is difficult. Accordingly, an object of the present invention is to provide a method of creating NC data for machining curved surfaces in which any curved surface is adopted as a cutting boundary surface in the depth direction. The present invention relates to an NC data creation method for machining a curved surface having a cutting boundary surface in the depth direction. Data specifying a three-dimensional curved surface and a curved surface of a cutting boundary in the depth direction are inputted. When the three-dimensional curved surface is defined by a set of a plurality of point-sequence paths, a point sequence Q(i,j) of a tool nose corresponding to a machining point sequence A(i,j) is determined. Next, there is determined a projected point sequence B′(i,j) obtained by projecting the point sequence Q(i,j) of the tool nose onto a reference plane, as well as a projected point sequence C(i,j) obtained by projecting the first-mentioned projected point sequence onto the curved surface of the cutting boundary. Thereafter, a check is performed to see whether a line segment connecting the point sequence Q(i,j) of the tool nose and a line segment connecting the projected point sequence C(i,j) on the curved surface of the cutting boundary intersect. If they do intersect, NC data up to the point of intersection P(i,j) are created. NC data are subsequently created in the same manner upon performing a pick-feed. Brief Description of the Drawings Fig. 1 is a view for describing the general features of a method according to the present invention; Fig. 2 is a block diagram of an NC data creating apparatus for carrying out a method according to the present invention; Fig. 3 is a flowchart of a method of processing according to the invention; Fig. 4 is a view for describing point-sequence paths on a curved surface; Fig. 5 is a view showing the relationship among a point-sequence path, the center of a tool and the tool nose; Fig. 6 is a view for describing an example of the prior art; and Fig. 7 is a view for describing machining that is impossible with the prior-art method. Fig. 1 is a view for describing the general features of a method of creating NC data for machining a curved surface according to the invention. Numeral 101 denotes a three-dimensional curved surface to be machined, 102 a curved boundary surface specifying the cutting limits of the curved surface 101, 103 an X-Y reference plane, 11i an i-th point-sequence path on the machined curved surface 101, A(i,j) a j-th point on the point-sequence path 11i, B(i,j) an offset point of a tool TL, with the point A(i,j) serving as a machining point, Q(i,j) a tool nose point, and C(i,j) a point on the curved boundary surface 102 corresponding to a projected point B′(i,j) obtained by projecting the point B(i,j) on the X-Y plane. P(i,j) represents the point of intersection between a line segment Q(i,j-1)Q(i,j) connecting a series of points of the tool nose, and a line segment C(i,j-1)C(i,j) connecting projected points on the curved boundary surface 102 corresponding to the abovementioned series of points of the tool nose. In the present invention, the first step is to enter data specifying the first three-dimensional curved surface desired to be machined as well as data specifying the second three-dimensional curved surface 102 which provides the cutting boundary of the first three-dimensional curved surface in the depth direction, and define the first machined surface 101 and the second curved boundary surface 102 by respective sets of a plurality of point-sequence paths on these curved surfaces. The method of determining a plurality of point sequences on a curved surface from curved surface data is well known. For example, such a method is disclosed in the specifications of USP 4,569,014 and USP 4,589,062. Next, the tool offset point sequence B(i,j) corresponding to the point sequence A(i,j) on the machining curved surface 101 is determined, the point sequence Q(i,j) of the tool nose, the projected point sequence B'(i,j) obtained by projecting the tool nose point sequence onto the X-Y plane 103, and the projected point sequence C(i,j) obtained by projecting the abovementioned projected point sequence onto the curved boundary surface 102. Thereafter, a check is performed to see whether the line segment Q(i,j-1)Q(i,j) connecting the tool nose point sequence and the line segment C(i,j-1)Q(i,j) connecting the projected point sequence on the curved boundary surface 102 intersect. If the line segments intersect, a tool offset line segment up to the point of intersection P(i,j) is outputted and NC data are created. This is followed by a pick-feed and NC data creation performed in the same manner. Fig. 2 is a block diagram of an NC data creating apparatus capable of practicing the present invention, and Fig. 3 is a flowchart of a preferred example of processing according to the invention. In Fig. 2, numeral 201 denotes a keyboard for data input; 202 a processor; 203 a ROM storing a control program for creating NC data; 204 a RAM; 205 a working memory; 206 a curved surface memory for storing generated curved surface data, 207 an output unit for outputting generated curved surface data to an external storage medium 208 such as a paper tape or magnetic tape; 209 an address bus; and 210 a data bus. A preferred example of creating NC data for machining a curved surface in accordance with the invention will now be described in detail with reference to the flowchart of Fig. 3. First, data specifying the first three-dimensional curved surface 101 (Fig. 1) desired to be machined as well as data specifying the second three-dimensional curved surface (curved boundary surface) 102 which provides the cutting boundary of the first three-dimensional curved surface in the depth direction are entered from the keyboard 201. These entered data are stored in the RAM 204. It should be noted that the three-dimensional curved surfaces are specified by drive curves 1a, 1b and base curves 1c, 1d, as shown in Fig. 4. Accordingly, these curve data are entered (step 301). When the data for specifying the curved surfaces have been entered, the procesor 202 generates the first machining curved surface 101 and the second curved boundary surface 102 in accordance with the well-known technique disclosed in the abovementioned USP specifications. In curved surface generation processing, an intermediate section curve 11i (i = 0, 1, 2, ... M; see Fig. 4), which is a point-sequence path, is generated, and a curved surface is generated by a set of these intermediate section curves (step 302). Next, the processor 202 performs the operations 0 → i, 0 → j (step 303), and a j-th point A(i,j) of an i-th path 11i on the machining curved surface 101 is determined (step 304). When the point A(i,j) has been found, a normal line to the path 11i is erected at the point A(i,j), the center (offset point) B(i,j) of the tool offset by the tool radius R is found, and the tool nose pcint Q(i,j) is determined (step 305; see Fig. 5). A method of determining the normal line direction is well known and disclosed in the specification of USP 4,559,601. Determined next is the projected point B′(i,j) obtained by dropping the tool offset point B(i,j) or the tool nose point Q(i,j) perpendicularly onto the X-Y plane (step 306). When the projected point B′(i,j) on the X-Y plane has been obtained, this projected point is elevated perpendicularly to obtain the projected point C(i,j) on the curved boundary surface 102 (step 307). A method of obtaining a projected point on a curved surface is well known. For example, this method is disclosed in International Laid-Open No. W086/05289 (Title: "Complex Curved Surface Creation Method"; Laid-Open Date: September 12, 1986). Thereafter, it is checked to see if the line segment Q(i,j-1)Q(i,j) connecting the tool nose point sequence and the line segment C(i,j-1)Q(i,j) connecting the projected point sequence on the curved boundary surface 102 intersect (step 308). If the line segments do not intersect, the processor 202 stores the point B(i,j) in the curved surface memory 206, performs the operation j + 1 → j to increment j, and repeats processing from step 304 onward (step 309). If these line segments do intersect, on the other hand, the point of intersection P(i,j) is obtained (step 310). The processor 202 determines an offset point B e (i,j), which is higher by the tool radius R in the Z direction than the point of intersection P(i,j), and stores the offset point B e (i,j) in the curved surface memory 206 (step 311). Next, it is determined whether i = M holds (step 312). Note that the M-th point-sequence path is the final point-sequence path. If i ≠ M is found to hold, the processor 202 performs the operation i + 1 → i to increment i and then repeats processing from step 304 onward (step 313). If i = M is found to hold in the determination of step 312, processing is terminated. This is followed by creating NC data for curved surface machining using the point sequence data stored in the curved surface memory 206, and outputting the NC data to the external storage medium 208 via the output unit 207. Thus, in accordance with the present invention, it is arranged to create NC data by designating a cutting boundary in the depth direction by any curved surface and outputting machining points up to the cutting boundary. This makes it possible to machine parts, such as TV frames, in which the boundary in the depth direction varies three-dimensionally.

Claims: A method of creating NC data for curved surface machining, characterized by comprising: a first step of inputting data specifying a first three-dimensional surface (101) to be machined and data specifying a second three-dimensional surface (102) which provides a cutting boundary of said first three-dimensional surface (101) in a depth direction being perpendicular to a reference plane (103); a second step of determining a point sequence (Qi,j) to be traversed by a tool nose and corresponding to a machining point sequence (Ai,j) on said first curved surface (101) when the first three-dimensional curved surface (101) is defined by a set of a plurality of point-sequence paths (11i) which are to be machined by said tool and which are generated by using said data; a third step of determining a projected point sequence (B′i,j) obtained by projecting said tool nose point sequence (Qi,j) onto said reference plane (103), and determining a projected point sequence (Ci,j) on the second curved surface (102) obtained by projecting said first-mentioned projected point sequence (B′i,j) onto the second curved surface (102); a fourth step of checking to see whether a line segment connecting the tool nose point sequence (Qi,j) and a line segment connecting the projected point sequence (Ci,j) on said second curved surface (102) intersect; a fifth step of creating NC data up to a point of intersection P(i,j) where the line segments intersect; and a sixth step of subsequently performing a pick-feed and creating NC data in the same manner. A method of creating NC data for curved surface machining according to claim 1, characterized in that if a tool central axis is aligned in a perpendicular direction, said second step includes determining a normal line direction at a point on said first surface (101); determining a tool center offset in said direction by a tool radius R, determining a point underlying the tool center (Bi,j) by the tool radius R, and adopting this point (Qi,j) as the tool nose. A method of creating NC data for curved surface machining according to claim 2, characterized in that said fifth step includes determining a point B e (i,j) higher by the tool radius in a Z direction than the point of intersection P(i,j), outputting the tool center B(i,j) up to a point just short of the point of intersection, and finally outputting the point B e (i,j).

Inventors: HANAOKA OSAMU, SAMUKAWA KOJI, SEKI MASAKI, HANAOKA, OSAMU, SAMUKAWA, KOJI, SEKI, MASAKI
Applicants: FANUC LTD, FANUC LTD.
Application year: 1988
Main classification: G05B19
IPC codes: G05B19