Area Cutting Method

This application is related to U.S. application Ser. Nos. 767,797; 767,265; 768,118; 776,205, and 744,746.

1. Field of the Invention

This invention relates to an area cutting method in a numerically controlled machine tool and, more particularly, to an area cutting method for cutting the interior of an area bounded by the curve of an external shape.

2. Description of the Related Art

Types of numerically controlled machining include cutting in which the interior of an area bounded by the curve of an external shape, for example the curve of an external shape comprising straight lines and circular arcs, is hollowed out down to a predetermined depth, and die milling in which the interior of an area is die milled. In such machining, as shown in FIG. 1(A), an area cutting method is conventionally carried out by performing cutting along an (i-1)th cutting path PTi-1 in one direction (the direction of the solid line arrow), moving the tool a predetermined amount at the completion of cutting, then positioning the tool directly above a cutting starting point Ps on the next, or i-th, cutting path PTi, thereafter lowering the tool to the cutting starting point Ps, moving the tool along the i-th cutting path PTi in the direction of the solid line arrow, and subsequently repeating the above unidirectional cutting.

Another area cutting method shown in FIG. 1(B) includes, following completion of cutting along the cutting path PTi-1 of the (i-1)th cutting path, moving the tool from a cutting end point Pe to the cutting starting point Ps on the next, or i-th, cutting path, and thereafter performing cutting along the i-th cutting path PTi. Thus, cutting is performed back and forth reciprocatively in the direction of the arrows.

Still another or third area cutting method shown in FIG. 1(C) includes obtaining offset paths OFC1, OFC2, . . . OFCn offset by predetermined amounts with respect to a curve OLC of an external shape, and moving the tool successively along the offset paths.

However, with the first area cutting method FIG. 1(A) based on unidirectional cutting, the tool must be positioned at the cutting starting point Ps on the i-th cutting path PTi after the completion of cutting along the (i-1)th cutting path PTi-1. This method is disadvantageous in that it results in a long tool travelling distance.

With the second cutting method FIG. 1(B) based on reciprocative cutting, portions are left uncut. In order to cut the uncut portions, the tool must be moved along the external shape curve OLC at completion of the back-and-forth cutting, thereby necessitating both back-and-forth cutting control and cutting control along the shape of the external curve. Accordingly, this method is disadvantageous in that the cutting control is complicated. Further, if an area AR has concavities and convexities, as shown in FIG. 1(D), the second method requires movement for achieving positioning indicated by the dashed lines. This is disadvantageous in that tool travelling distance and cutting time are prolonged. In addition, since the cutting process for the outward trip is different from the cutting process for the return trip, cutting cannot be performed efficiently overall. It should be noted that the cutting processes referred to here indicate up cutting and down cutting processes. FIGS. 2(A) and 2(B) show examples of the down cutting process, and FIGS. 2(C) and 2(D) depict examples of the up cutting process. If the workpiece material has been determined, then a cutting method capable of cutting the workpiece efficiently is selected from the up cutting and down cutting processes. However, with the second method [FIG. 1(B)], the up cutting process [e.g., FIG. 2(A)] and the down cutting process [e.g., FIG. 2(C)] are always mixed, so that cutting cannot be performed efficiently.

With the third method [FIG. 1(C)] of cutting along the offset paths, portions are left uncut at, e.g., the central portion of the area, depending upon the contour of the external shape curve. This method is disadvantageous in that dealing with these uncut portions is a complicated task.

Accordingly, an object of the present invention is to provide an area cutting method whereby the interior of an area can be cut continuously and efficiently without requiring control for raising a tool, positioning the tool at the next cutting starting point and then lowering the tool.

Another object of the present invention is to provide an area cutting method wherein portions are not left uncut.

An area cutting method for cutting the interior of an area bounded by a closed curve has a step of calculating a centroid of an area bounded by a closed curve. After calculating the centroid, a step is preformed for determining whether each line segment connecting the centroid with each vertex of the area intersects the closed curve followed by a step of partitioning each line segment into a predetermined number of partitions if the line segment does not intersect the closed curve. Next a step is executed for performing area cutting by moving a tool along plural closed paths each of which is obtained by connecting corresponding ones of the partitioning points of respective line segments. A step, which is executed if at least one line segment intersects the closed curve, is performed for partitioning the area into a plurality of regions, calculating the centroid of each partitioned region, partitioning each line segment connecting the centroid with each vertex of the partitioned region corresponding to the centroid into a predetermined number of partitions, finding plural closed curves, for each and every partitioned region, obtained by connecting corresponding ones of the partitioning points of the line segments, followed by performing area cutting by successively moving the tool along each closed path.

FIGS. 1(A)-1(D) are views for describing the conventional area cutting method.

FIGS. 2(A)-2(D) are views for describing up cutting and down cutting processes;

FIG. 3. is a view for describing the general features of the present invention;

FIG. 4 is a block diagram of an embodiment of the present invention;

FIGS. 5(A) and 5(B) together produce a flowchart of processing indicative of the area cutting method of the present invention;

FIG. 6 is a view for describing a method of calculating an offset curve;

FIGS. 7(A) and 7(B) are views for describing a method of linear approximation of a circular arc curve portion;

FIG. 8 is a view for describing a method of calculating a centroid; and

FIGS. 9(A) and 9(B) are views for describing the area cutting method of the present invention for a case where the area has a complicated shape.

FIG. 4 is a block diagram of an embodiment of the present invention, and FIG. 5 is a flowchart of processing performed thereby. The area cutting method of the present invention will now be described with reference to FIGS. 3 through 5.

Area cutting data necessary for area cutting 13 recorded at appropriate locations on an NC tape or in a memory (assumed to be an NC tape hereafter) 101. Specifically, in addition to ordinary numerical control data, area cutting instructions, coordinate values (x.sub.j,y.sub.j) of the vertices Q1, Q2, Q3, . . . Qn of the area, the radius r.sub.j of each circular arc, finishing margin t, cut-in pitch P, cutting velocity fc, and data for identifying the end of the area cutting data, are recorded on the NC tape 101. Note that the positions of the apices and the radii of the circular arcs are commanded in sets in the form, e.g., (x.sub.j,y.sub.j,r.sub.j), with r.sub.j =0 for straight lines. Accordingly, in the area cutting of the area AR shown in FIG. 3, the area is specified by

Xx.sub.1 Yy.sub.1 R0;

Xx.sub.2 Yy.sub.2 R0;

Xx.sub.3 Yy.sub.3 R0;

Xx.sub.4 Yy.sub.4 R0;

Xx.sub.5 Yy.sub.5 R0;

Xx.sub.6 Yy.sub.6 R0;

Xx.sub.7 Yy.sub.7 Rr;

(1) As illustrated in FIGS. 5(A) and 5(B), when a cycle start button on an operator's panel 102 is pressed to start the system, a processor 103 causes an NC data reader 104 to read one block of NC data from an NC tape 101.

(2) Next, under the control of a control program stored in a ROM 105, the processor 103 decodes the read NC data and determines whether the NC data are indicative of program end "M02" or tape end "M30".

(3) If program end or tape end is indicated, processing is stopped. If the NC data are path data, then these data are delivered to a pulse distributor 106. If an item of NC data is an M-, S- or T-function instruction to be delivered to the machine side, then the instruction is applied to a machine tool 108 through a magnetics circuit 107. If an item of data is an area cutting instruction, then the NC data reader 104 is caused to read the area cutting data.

When an item of NC data is path data, the processor 103 finds incremental values Xi, Yi, Zi along the respective axes. The processor 103 then uses a three-dimensional command velocity F and the incremental values Xi, Yi, Zi along the respective axes to obtain velocity components F.sub.x, F.sub.y, F.sub.z along the respective axes from equations: ##EQU1## and thereafter obtains travelling quantities .sub..DELTA. X, .sub..DELTA. Y, .sub..DELTA. Z, which are to be traversed along the respective axes in a predetermined period of time .sub..DELTA. T seconds (=16 msec), from equations:

The processor delivers .sub..DELTA. X, .sub..DELTA. Y, .sub..DELTA. Z to the pulse distributor 106 every .sub..DELTA. T sec. Note that .sub..DELTA. T is stored beforehand in a parameter memory 109.

On the basis of the input data, the pulse distributor 106 performs a simultaneous three-axis pulse distribution calculation to generate distributed pulses Xp, Yp, Zp. These are delivered to servo circuits 110X, 110Y, 110Z for the respective axes to transport the tool along the cutting path.

The processor 103, in accordance with the following formulae, updates the present position X.sub.a, Y.sub.a Z.sub.a every .sub..DELTA. T sec, X.sub.a, Y.sub.a, Z.sub.a having been stored in a RAM 111:

The sign depends upon the direction of movement. Similarly, in accordance with the following formulae, the processor 103 updates remaining traveling distances X.sub.r, Y.sub.r, Z.sub.r (the initial values of which are the incremental values X.sub.i, Y.sub.i, Z.sub.i, respectively) every .sub..DELTA. T sec, X.sub.r, Y.sub.r, Z.sub.r having been stored in the RAM 111:

When the following condition is established or true:

the processor 103 treats this as indicating that the movable element has arrived at a target position and causes the NC data reader 104 to read the next item of NC data.

(4) If an item of NC data read from the NC tape 101 is found to be an area cutting command, the processor 103 causes the NC data reader 104 to read the area cutting data and store the data in the RAM 111 until the code indicating the end of the area cutting data is read out.

(5) When the reading of the area cutting data ends, the processor 103 calculates the offset curve OFC, which is offset from the curve OLC (FIG. 3) of the external shape by a distance D=ra+t, the latter being obtained by adding the tool radius ra and the finishing margin t. It should be noted that the tool radius ra is obtained by reading a radius value corresponding to a commanded tool number from an offset memory 112, which stores the correspondence between tool numbers and tool radii. The offset curve OFC is found through the following processing. Specifically, as shown in FIG. 6, let two straight lines specifying the curve OLC of the external shape be S1 and S2. Straight lines S1', S2' offset from the straight lines S1, S2, respectively, by the distance D are found. The intersection P2 of the straight lines S1', S2' is then found. The intersection P2 is one point specifying the offset curve OFC. Accordingly, if points of intersection are found in a similar manner and stored in the RAM 111, the offset curve OFC will be obtained.

(6) The processor 103 now linearly approximates the circular arc portion of the offset curve OFC. In performing the linear approximation processing, it is so arranged that the maximum distance between the circular arc portion and the straight line takes on a value smaller than the cut-in pitch P. FIG. 7 is a view for describing the linear approximation processing.

For a case where the inner side of a circular arc A1 is the area to be cut, as shown in FIG. 7(A), the maximum distance d between the circular arc A1 and the straight line LN is given by

where the radius of the arc is r and the central angle of the line LN is .theta.. Accordingly, the central angle .theta. for which d.ltoreq.P holds, namely the central angle 0 that satisfies the relation:

is found, the central angle .phi. of the circular arc A1 is partitioned at the angle .theta. and the coordinate values of each partitioning point R.sub.i are stored in the RAM 111. This ends the processing for linear approximation of the interior of the arc. If we let the coordinate values of the starting point P7 of circular arc A1 be (x.sub.7,y.sub.7), then the coordinate values (x.sub.i,y.sub.i) of an i-th partitioning point R.sub.i, for a case where the arc center CN is taken as the origin, may be calculated from the equations:

For a case where the outer side of a circular arc A1 is the area to be cut, as shown in FIG. 7(B), the maximum distance d between the circular arc A1 and the straight line LN is given by:

Accordingly, the angle .theta. for which d.ltoreq.P holds, namely the angle .theta. that satisfies the relation:

is found, the point R.sub.i linearly approximating the circular arc portion on the basis of .theta. is found, and this is stored in the RAM 111. This ends the processing for linear approximation of the exterior of an arc.

(7) When the linear approximation processing ends, the processor 103 calculates the centroid W of an area (a polygon) bounded by an offset curve OFC' (see FIG. 3) obtained by the linear approximation. The coordinate values of the centroid of the area (polygon) are calculated through the following processing. Specifically, as shown in FIG. 8, a polygon PG is broken down into a plurality of triangles TR1 through TR3 and the centroids W11 through W13 and areas SQ1 through SQ3 of the respective triangles are calculated. Next, a point W21 that divides a line segment W12W11 connecting the centroids W11, W12 into the ratio SQ1:SQ2 (area ratio) is found. Note that the point W21 is the centroid of a quadrilateral P1P2P3P4. After the point W21 is calculated, a point W is found that divides a line segment W13W21 into the area ratio (SQ1+SQ2):SQ3. The point W is the centroid of the polygon PG.

(8) When the centroid W (FIG. 3) of the area is found, the processor 103 determines whether line segments L1-L10 connecting the centroid W with each of the vertices P1-P10 of the area intersect the linearly approximated offset curve OFC'. The term "intersect" as used here refers to a state in which, as shown in FIG. 9(A), the line segment L6 connecting the centroid W with the vertex P6 of the polygon P1P2 . . . P7 crosses the offset curve OFC'.

(9) If none of the line segments L1-L10 intersects the offset curve OFC', then the processor obtains, and stores in the RAM 111, the coordinate values of partitioning points:

P.sub.a1, P.sub.b1, . . . P.sub.n1 ;

P.sub.a2, P.sub.b2, . . . P.sub.n2 ;

P.sub.a3, P.sub.b3, . . . P.sub.n3 ;

. .

P.sub.a10, P.sub.b10, . . . P.sub.n10 ;

that partition, into a predetermined number of partitions n, each of the line segments L1-L10. As for the number n of partitions, the length l of the longest of all the above-mentioned lines segments L1-L10 is found, after which an n is determined that satisfies the relation:

(10) When the coordinate values of the partitioning points of each of the line segments are found, plural closed paths CPT1, CPT2, . . . CPTn obtained by connecting the partitioning points are generated:

P.sub.a1, P.sub.a2, P.sub.a3 . . . P.sub.a10 ;

P.sub.b1, P.sub.b2, P.sub.b3 . . . P.sub.b10 ;

. .

P.sub.n1, P.sub.n2, P.sub.n3 . . . P.sub.n10 ;

that correspond to each of the foregoing line segments, the tool is moved along each closed path and finally along the offset curve OFC or OFC'. The area AR can thus be cut. Accordingly, by using the coordinate values of the starting point P.sub.a1 of the first closed path CPT1 stored in the RAM 111 through the above-described processing, the processor 103 obtains numerical data (incremental values between an initial position and the starting point P.sub.a1) for making the tool approach the starting point P.sub.a1 from the initial position, and thereafter executes path control based on the above-mentioned Eqs. (1a) through (5) by using the incremental values. When the approach is completed, the processor moves the tool to the point P.sub.a2 along the first closed path CPT1 in a cutting feed mode and thereafter successively moves the tool along the first closed path in the manner P.sub.a2 .fwdarw.P.sub.a3 .fwdarw.P.sub.a4 . . . .fwdarw.P.sub.a10 to perform cutting. When the cutting along the first closed path ends, the tool is shifted to the point P.sub.b1 (P.sub. a1 .fwdarw.P.sub.b1) in the cutting feed mode and cutting is subsequently performed along the second closed path CPT2, third closed path CPT3, . . . n-th closed path CPTn. Finally, the tool is moved along the offset curve OFC or OFC' in accordance with the data specifying the offset curve OFC or OFC' stored in the RAM 111. This ends the area cutting processing. Thereafter, the next item of NC data is read from the NC tape and the foregoing processing is repeated.

Though a case has been described where the tool movement sequence is CPT1.fwdarw.CPT2.fwdarw. . . . .fwdarw.CPTn.fwdarw.OFC when performing cutting, the present invention is not limited to this sequence, for movement along the offset curve OFC (OFC') can be performed first. Further, it is possible to adopt an arrangement wherein an NC tape is prepared by the above-described method using area cutting data and the NC tape is loaded into an NC unit to cut the area.

(11) In a case where at least one of the line segments from among the line segments L1-L10 connecting the centroid with the vertices intersects the linearly approximated offset curve OFC', the area (polygon) bounded by this linearly approximated offset curve OFC' is partitioned into a plurality of regions. This area partitioning operation is carried out through the following sequence, which serves as an example [see FIG. 9(A)]:

(a) It is determined whether line segment Li connecting the centroid W with the i-th (the initial value of i is 1) vertex Pi intersects the offset curve OFC'.

(b) If no intersection occurs, the operation i+1.fwdarw.i is performed and the decision process of step (a) is performed.

(c) If an intersection occurs, the polygon P1P2P3 . . . Pi-1 is treated as a first partitioned region AR.sub.1.

(d) Thereafter, the centroid of the polygon PiPi+1 . . . P1 is found and the processing of steps (a)-(c) is repeated for the polygon PiPi+1 . . . P1.

The foregoing processing partitions the area into a plurality of regions. (In the example of FIG. 9, the area is partitioned into two regions AR1, AR2.)

(12) When the area partitioning processing ends, the centroids W1, W2 of the respective partitioned regions AR1, AR2 are obtained, processing similar to that described above is performed to obtain plural closed paths CPT11-CPT1n, CPT21-CPT2m in the respective partitioned regions AR1, AR2, and area cutting is performed by moving the tool along these closed paths.

Thus, according to the present invention, area cutting can be performed while moving a tool in a continuous manner. This eliminates wasted tool motion, raises the efficiency of cutter passes and shortens machining time.

Further, according to the present invention, the distance between i-th and (i+1)th closed paths is changed in dependence upon the shape to be cut, with the result that portions are not left uncut at the central and other parts of the area.

Still further, according to the present invention area cutting is performed in a simple manner merely by finding a centroid, partitioning straight lines connecting the centroid with the vertices of the area into a predetermined number of segments, and successively moving the tool along the closed paths connecting corresponding ones of the partitioning points.

In addition, according to the present invention, tool paths can be generated automatically merely by entering area cutting data.

The present invention is well-suited for application to area cutting performed by machine tools, or to the creation of NC data for area cutting .