Compensation of deformation errors in five-axis flank milling of thin-walled parts via tool path optimization

2019 ◽  
Vol 55 ◽  
pp. 77-87 ◽  
Author(s):  
Zhou-Long Li ◽  
Li-Min Zhu
Keyword(s):  
Tool Path ◽  
Path Optimization ◽  
Flank Milling ◽  
Tool Path Optimization ◽  
Thin Walled ◽  
Five Axis

Envelope Surface Modeling and Tool Path Optimization for Five-Axis Flank Milling Considering Cutter Runout

2014 ◽  
Vol 136 (4) ◽  
Author(s):  
Zhou-Long Li ◽  
Li-Min Zhu
Keyword(s):  
Distance Function ◽  
Tool Path ◽  
Surface Modeling ◽  
Path Optimization ◽  
Mixed Integer ◽  
Flank Milling ◽  
Cutter Runout ◽  
Tool Path Optimization ◽  
Envelope Surface ◽  
Five Axis

Cutter runout is a common and inevitable phenomenon impacting the geometry accuracy in the milling process. However, most of the works on tool path planning neglect the cutter runout effect. In this paper, a new approach is presented to integrate the cutter runout effect into envelope surface modeling and tool path optimization for five-axis flank milling with a conical cutter. Based on the geometry model of cutter runout which consists of cutter axis and cutter tilt, an analytic expression of cutter edge combined with four runout parameters is derived. Then the envelope surface formed by each cutter edge is constructed using the envelope theory of sphere congruence. Due to the cutter runout effect, the envelope surfaces formed by the cutter edges are different from each other, and the valid envelope surface is the combination of these envelope surfaces which contribute to the final machined surface. To measure the machining errors, the geometry deviations between the valid envelope surface and the design surface are calculated with the distance function. On the basis of the differential property of the distance function, tool path optimization considering cutter runout is modeled as a mixed-integer linear programming (MILP) problem, which can be solved by the branch-and-bound method. Finally, numerical examples are given to confirm the validity and efficiency of the proposed approach. The results show that the geometry errors induced by runout can be reduced significantly using the proposed method.

Feed Optimization for Five-Axis Flank Milling Thin-Walled Parts

2014 ◽  
Vol 703 ◽  
pp. 150-155
Author(s):  
Ming Yong Wang
Keyword(s):  
Process Optimization ◽  
Sequential Quadratic Programming ◽  
Tool Path ◽  
Milling Process ◽  
Flank Milling ◽  
Machining Time ◽  
Mechanics Model ◽  
Finished Surface ◽  
Thin Walled ◽  
Five Axis

This paper presents process optimization for the five-axis milling based on the mechanics model explained in Part I. The process is optimized by varying the feed as the tool-workpiece engagements. The linear and angular feedrates are optimized by sequential quadratic programming. Sharp feedrate changes may result in undesired feed-marks on the finished surface. The adopted step is to update the the original CL file with optimized and filtered feedrate commands. The five-axis milling process is simulated in a virtual enviroment, and the resulting feedrate outputs are stored at each position along the tool path. The new feedrate profiles are shown to considerably reduce the machining time while avoiding process faults.

Smooth Tool Path Optimization for Flank Milling Based on the Gradient-Based Differential Evolution Method

2016 ◽  
Vol 138 (8) ◽  
Author(s):  
YaoAn Lu ◽  
Ye Ding ◽  
LiMin Zhu
Keyword(s):  
Differential Evolution ◽  
Coordinate System ◽  
Optimization Model ◽  
Tool Path ◽  
Path Optimization ◽  
Flank Milling ◽  
Tool Path Optimization ◽  
Rotary Axes ◽  
Gradient Based ◽  
Geometric Deviation

Flank milling is one of the most important technologies for machining of complex surfaces. A small change of the tool orientation in the part coordinate system (PCS) may produce a great rotation of the rotary axes of the machine tool. Therefore, this paper proposes a tool path optimization model for flank milling in the machine coordinate system (MCS). The tool path is computed to smooth the variation of the rotary axes while controlling the geometric deviation. The geometric deviation is measured by the signed distance between the design surface and the tool envelope surface in the PCS. The geometric accuracy is not an objective but a constraint in the proposed optimization model. Given a prescribed geometric tolerance, the tool path smoothness optimization model is reformulated as a constrained nonlinear programming problem. The ε constrained differential evolution with gradient-based mutation (εDEg) is adopted to solve this constrained problem. The validity of the proposed approach is confirmed by numerical examples.

Adaptive nonlinear tool path optimization for five-axis machining

2000 ◽  
Vol 38 (17) ◽  
pp. 4329-4343 ◽  
Author(s):  
E. Bohez ◽  
S.S. Makhanov ◽  
K. Sonthipermpoon
Keyword(s):  
Tool Path ◽  
Path Optimization ◽  
Tool Path Optimization ◽  
Five Axis
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