Virtual Five-Axis Flank Milling of Jet Engine Impellers—Part II: Feed Rate Optimization of Five-Axis Flank Milling

2008 ◽  
Vol 130 (1) ◽  
Author(s):  
W. B. Ferry ◽  
Y. Altintas
Keyword(s):  
Feed Rate ◽  
Tool Path ◽  
Fixed Time ◽  
Flank Milling ◽  
Tool Deflection ◽  
Jet Engine ◽  
Root Finding ◽  
Five Axis ◽  
Feed Rate Optimization ◽  
Chip Load

This paper presents process optimization for the five-axis flank milling of jet engine impellers based on the mechanics model explained in Part I. The process is optimized by varying the feed automatically as the tool-workpiece engagements, i.e., the process, vary along the tool path. The feed is adjusted by limiting feed-dependent peak outputs to a set of user-defined constraints. The constraints are the tool shank bending stress, tool deflection, maximum chip load (to avoid edge chipping), and the torque limit of the machine. The linear and angular feeds of the tool are optimized by two different methods—a multiconstraint based virtual adaptive control of the process and a nonlinear root-finding algorithm. The five-axis milling process is simulated in a virtual environment, and the resulting process outputs are stored at each position along the tool path. The process is recursively fitted to a first-order process with a time-varying gain and a fixed time constant, and a simple proportional-integral controller is adaptively tuned to operate the machine at threshold levels by manipulating the feed rate. As an alternative to the virtual adaptive process control, the feed rate is optimized by a nonlinear root-finding algorithm. The virtual cutting process is modeled as a black box function of feed and the optimum feed is solved for iteratively, respecting tool stress, tool deflection, torque, and chip load constraints. Both methods are shown to produce almost identical optimized feed rate profiles for the roughing tool path discussed in Paper I. The new feed rate profiles are shown to considerably reduce the cycle time of the impeller while avoiding process faults that may damage the part or the machine.

Virtual Five-Axis Flank Milling of Jet Engine Impellers: Part 2 — Feed Rate Optimization of Five-Axis Flank Milling

2007 ◽  
Author(s):  
W. Ferry ◽  
Y. Altintas
Keyword(s):  
Feed Rate ◽  
Tool Path ◽  
Flank Milling ◽  
Tool Deflection ◽  
Jet Engine ◽  
Root Finding ◽  
Non Linear ◽  
Five Axis ◽  
Feed Rate Optimization ◽  
Chip Load

This paper presents optimization schemes for the five-axis flank milling of jet engine impellers based on the mechanics model explained in Part I. The process is optimized by varying the feed automatically as the tool-workpiece engagements, i.e. the process, varies along the tool path. The feed is adjusted by limiting feed-dependent peak outputs to a set of user-defined constraints. These outputs are tool shank bending stress, tool deflection, maximum chip load (to avoid edge chipping) and the torque limit of the machine. The linear and angular feeds of the machine are optimized by two different methods — a multi-constraint based virtual adaptive control of the process and a non-linear root finding algorithm. The five-axis milling process is simulated in a virtual environment, and the resulting process outputs are stored at each position along the tool path. The process is recursively fitted to a first order process with a time varying gain and a fixed time constant, and a simple Proportional Integral controller is adaptively tuned to operate the machine at threshold levels by manipulating the feedrate. As an alternative to virtual adaptive process control, the feedrate is optimized by a non-linear root-finding algorithm. The optimum feed is solved for iteratively, respecting tool stress, tool deflection, torque and chip load constraints, using a non-linear root finding algorithm. Both methods are shown to produce almost identical optimized feed rate profiles for the roughing tool path discussed in Part I of the paper. The new feed rate profiles are shown to considerably reduce the cycle time of the impeller while avoiding process faults that may damage the part or the machine.

scholarly journals Cutting force and machine kinematics constrained cutter location planning for five-axis flank milling of ruled surfaces

2017 ◽  
Vol 4 (3) ◽  
pp. 203-217 ◽  
Author(s):  
Ke Xu ◽  
Jiarui Wang ◽  
Chih-Hsing Chu ◽  
Kai Tang
Keyword(s):  
Cutting Force ◽  
Surface Quality ◽  
Feed Rate ◽  
Tool Path ◽  
Flank Milling ◽  
Machining Efficiency ◽  
Location Planning ◽  
Tool Positioning ◽  
Finished Surface ◽  
Five Axis

Abstract Five-axis flank milling has been commonly used in the manufacturing of complex workpieces because of its greater productivity than that of three-axis or five-axis end milling. The advantage of this milling operation largely depends on effective cutter location planning. The finished surface sometimes suffers from large geometrical errors induced by improper tool positioning, due to the non-developability of most ruled surfaces in industrial applications. In addition, a slender flank-milling cutter may be deflected when subjected to large cutting forces during the machining process, further degrading the surface quality or even breaking the cutter. This paper proposes a novel tool path planning scheme to address those problems. A simple but effective algorithm is developed to adaptively allocate a series of cutter locations over the design surface with each one being confined within an angular rotation range. The allocation result satisfies a given constraint of geometrical errors on the finished surface, which consists of the tool positioning errors at each cutter location and the sweeping errors between consecutive ones. In addition, a feed rate scheduling algorithm is proposed to maximize the machining efficiency subject to the cutting force constraint and the kinematical constraints of a specific machine configuration. Simulation and experimental tests are conducted to validate the effectiveness of the proposed algorithms. Both the machining efficiency and finish surface quality are greatly improved compared with conventional cutter locations. Highlights Tool position is bounded with respect to the geometrical machining error. Cutting force and kinematics during five-axis flank milling process are analyzed. An incremental adaptive flank milling tool path generation algorithm is proposed. Feed rate is smoothly assigned respecting cutting force and kinematic constraints.

Research on Five-Axis Dual-NURBS Adaptive Interpolation Algorithm for Flank Milling

2010 ◽  
Vol 443 ◽  
pp. 330-335 ◽  
Author(s):  
Yu Han Wang ◽  
Jing Chun Feng ◽  
Sun Chao ◽  
Ming Chen
Keyword(s):  
Tool Path ◽  
Flank Milling ◽  
Interpolation Algorithm ◽  
Machining Time ◽  
Surface Machining ◽  
Tool Axis ◽  
Scanning Area ◽  
Nurbs Interpolation ◽  
Milling Method ◽  
Five Axis

In order to exploit the advantages of five-axis flank milling method for space free surface machining to the full, a definition of non-equidistant dual-NURBS tool path is presented first. On this basis, the constraint of velocity of points on the tool axis and the constraint of scanning area of the tool axis are deduced. Considering both of these constraints, an adaptive feed five-axis dual-NURBS interpolation algorithm is proposed. The simulation results show that the feedrate with the proposed algorithm satisfies both of the constraints and the machining time is reduced by 38.3% in comparison with the constant feed interpolator algorithm.

Global optimization of tool path for five-axis flank milling with a conical cutter

2010 ◽  
Vol 42 (10) ◽  
pp. 903-910 ◽  
Author(s):  
LiMin Zhu ◽  
Gang Zheng ◽  
Han Ding ◽  
YouLun Xiong
Keyword(s):  
Global Optimization ◽  
Tool Path ◽  
Flank Milling ◽  
Five Axis

Tool Path Planning for Five-Axis U-Pass Milling of an Impeller

2021 ◽  
Author(s):  
J.Y. Feng ◽  
Z.C. Wei ◽  
M.J. Wang ◽  
X.Q. Wang ◽  
M.L. Guo
Keyword(s):  
Path Planning ◽  
Cutting Force ◽  
Tool Path ◽  
Flank Milling ◽  
Small Range ◽  
Tool Path Planning ◽  
Point Distribution ◽  
Parameter Domain ◽  
Five Axis ◽  
Tool Axis Vector

Abstract U-pass milling is a roughing method that combines the characteristics of flank milling with conventional trochoidal milling. The tool cuts in and out steadily, and the tool–workpiece wrap angle is maintained within a small range. This method can smooth the cutting force and reduce the peak cutting force while avoiding cutting heat accumulation, which can significantly improve the processing efficiency and reduce tool wear. In this study, a tool path model is established for U-pass milling, and the characteristic parameters of the path are defined. Through a comparative test of three-axis groove milling, it is demonstrated that the peak value and average value of the cutting force are reduced by 25% and 60%, respectively. An impeller runner is considered as the processing object, and the milling boundary parameters are pretreated. A tiling micro-arc mapping algorithm is proposed, which maps the three-dimensional boundary to the two-dimensional parameter domain plane with the arc length as the coordinate axis, and the dimensionally reduced tool contact point distribution form is obtained. The geometric domain tool position point and the interference-free tool axis vector are obtained by calculating the bidirectional proportional domain of the runner and the inverse mapping of any vector in the parameter domain. Finally, the calculation results are nested into the automatically programmed tool (APT) encoding form, and the feasibility of the five-axis U-pass milling tool path planning method is verified through a numerical example.

A novel tool-path generation method for five-axis flank machining of centrifugal impeller with arbitrary surface blades

2016 ◽  
Vol 231 (1) ◽  
pp. 155-166 ◽  
Author(s):  
Hong-Zhou Fan ◽  
Shang-Jin Wang ◽  
Guang Xi ◽  
Yan-Long Cao
Keyword(s):  
Tool Path ◽  
Tool Path Generation ◽  
Ruled Surface ◽  
Centrifugal Impeller ◽  
Flank Milling ◽  
Path Generation ◽  
Rough Machining ◽  
Machining Time ◽  
Geometrical Structures ◽  
Five Axis

The centrifugal impeller with arbitrary surface blades is a very important component in automobile, ships, and aircraft industry, and it is one of the most difficult parts to process. Focusing on the machining efficiency improvement, combining the geometric advantages of ruled surface and arbitrary surface, and utilizing the efficient and accurate advantages of flank machining and point machining, this article presents a novel and targeted tool-path generation method and algorithm for five-axis flank machining of centrifugal impeller with arbitrary surface blades. In light of specific characters of different surfaces, the analyses of two different impeller blades are proposed first, the more characteristic and complex geometrical structures of the arbitrary blade are achieved. In rough machining, an approximate ruled surface blade is obtained, and a simple channel is achieved; the flank milling of the centrifugal impeller with ruled surface blades is achieved relative to the point milling of the centrifugal impeller with arbitrary surface blades; and the triangle tool path planning method is added in this process to save the machining time and cost collectively. Furthermore, in semi-finish machining, the approximate sub-ruled blade surfaces are calculated, and a new flank milling method of the sub-ruled blade surfaces is achieved; a new solution for tool interference is achieved in this process and the generation of non-interference tool paths becomes easy. Machining experiments of two different impellers are presented as a test of the proposed methods.

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