A kinematic model is presented to aid in the design of cam-profiles and determine the NC data equations using Denavit-Hartenberg (D-H) notation to produce and to measure the dimension accuracy of roller-gear cams on 5-axis machine tools. First, cam profiles are determined based on the conjugate surface theory. Then, D-H notation is employed in the derivation of machine tool ability functions and in the generation of the desired cutter/measuring-probe location matrices. The desired NC data equations are obtained by solving the link variables of the machine tool by equating the machine tool ability function with the tool location matrices. The resultant cutting speed and material-removal rate during machining are also investigated. To verify the validity of this methodology, a designed roller-gear cam was machined and its surfaces were measured through the on-line measurement system equipped with a touch-trigger probe on a 5-axis machine tool. This methodology combines the cam design, machining, and measurement techniques, thus making the production process more flexible, automatic, and controllable.

Issue Section:
Research Papers
Topics:
Cams, Gears, Machine tools, Machining, Rollers, Design, Probes, Cutting, Dimensions, Kinematics, Manufacturing, Measurement systems
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