Feed-rate control using fuzzy reasoning for NC machine tools

In this article, a 3D design and machining system based on an NC machine tool with a rotary unit is first introduced to effectively produce attractive paint rollers. A post-processor is proposed to transform a base tool path called cutter location data (CL data) to NC data, mapping the y-directional pick feed to the rotational angle of the rotary unit. The 3D machining system with the postprocessor allows us easily to transcribe a relief design on a flat model surface to a cylindrical model surface. The postprocessor has another function that systematically adjusts the feed-rate according to the curvature of each design to prevent the machined surface from being chipped. The post-processor generates suitable feed-rate codes by using a simple fuzzy reasoning method while checking the edges in relief designs. Experimental results show that wooden paint rollers with attractive relief designs can be successfully machined without undesirable edge chipping. Next, the proposed fuzzy feed-rate generator is further applied to a mold-polishing robot, so that the polishing time can be reduced by about 30% compared with the case without the generator.