scholarly journals A tool path optimization approach based on blend feature simplification for multi-cavity machining of complex parts

2019 ◽  
Vol 103 (1) ◽  
pp. 003685041987423
Author(s):  
Yupeng Xin ◽  
Shengqiang Yang ◽  
Gangfeng Wang ◽  
Richard Evans ◽  
Fengfeng Wu
Keyword(s):  
Tool Path ◽  
Spatial Distance ◽  
Prototype System ◽  
Optimization Approach ◽  
Improved Genetic Algorithm ◽  
Structural Part ◽  
Planning Approach ◽  
Automatic Tool ◽  
Geometric Elements ◽  
Corner Machining

Blend features usually exist in the machining of complex multi-cavity parts; however, the ideal linear boundary of the cavity is shown as an arc curve at actual corner machining, which affects the accuracy of a robot’s tool feed position. Focused on this problem, this article presents an automatic tool path planning approach based on blend feature simplification. By analyzing the geometric elements of blend feature, a line segment is constructed to obtain the machining boundary, while the robot tool feed position is accurately measured. On this basis, the coordinates of a robot tool feed position are assigned to the machining element, which can be used to calculate the spatial distance between different cavities. Then, an improved genetic algorithm is applied to improve the optimization of the tool path. The automatic decision of the corresponding work steps is realized by merging and sorting the machining elements. Finally, a corresponding prototype system is presented, with the correctness and validity of the proposed approach being examined, using aircraft structural part machining as an illustrative example.

scholarly journals Towards Efficient Milling of Multi-Cavity Aeronautical Structural Parts Considering ACO-Based Optimal Tool Feed Position and Path

Micromachines ◽  
2021 ◽  
Vol 12 (1) ◽  
pp. 88
Author(s):  
Yupeng Xin ◽  
Yuanheng Li ◽  
Wenhui Li ◽  
Gangfeng Wang
Keyword(s):  
High Speed ◽  
Tool Path ◽  
Milling Process ◽  
Ant Colony ◽  
Machining Accuracy ◽  
Ant Colony Optimization Algorithm ◽  
Peripheral Milling ◽  
Structural Part ◽  
Milling Method ◽  
Structural Parts

Cavities are typical features in aeronautical structural parts and molds. For high-speed milling of multi-cavity parts, a reasonable processing sequence planning can significantly affect the machining accuracy and efficiency. This paper proposes an improved continuous peripheral milling method for multi-cavity based on ant colony optimization algorithm (ACO). Firstly, by analyzing the mathematical model of cavity corner milling process, the geometric center of the corner is selected as the initial tool feed position. Subsequently, the tool path is globally optimized through ant colony dissemination and pheromone perception for path solution of multi-cavity milling. With the advantages of ant colony parallel search and pheromone positive feedback, the searching efficiency of the global shortest processing path is effectively improved. Finally, the milling programming of an aeronautical structural part is taken as a sample to verify the effectiveness of the proposed methodology. Compared with zigzag milling and genetic algorithm (GA)-based peripheral milling modes in the computer aided manufacturing (CAM) software, the results show that the ACO-based methodology can shorten the milling time of a sample part by more than 13%.

Tool Orientation Planning in Milling With Process Dynamic Constraints: A Minimax Optimization Approach

2018 ◽  
Vol 140 (11) ◽  
Author(s):  
Tao Huang ◽  
Xiao-Ming Zhang ◽  
Jürgen Leopold ◽  
Han Ding
Keyword(s):  
Tool Path ◽  
End Milling ◽  
Tool Path Generation ◽  
Optimization Approach ◽  
Path Generation ◽  
Tool Orientation ◽  
Minimax Optimization ◽  
Ball End Milling ◽  
Dynamic Constraints ◽  
Five Axis

In five-axis milling process, the tool path generated by a commercial software seldom takes the dynamics of the machining process into account. The neglect of process dynamics may lead to milling chatter, which causes overcut, quick tool wear, etc., and thus damages workpiece surface and shortens tool life. This motivates us to consider dynamic constraints in the tool path generation. Tool orientation variations in five-axis ball-end milling influence chatter stability and surface location error (SLE) due to the varying tool-workpiece immersion area and cutting force, which inversely provides us a feasible and flexible way to suppress chatter and SLE. However, tool orientations adjustment for suppression of chatter and SLE may cause drastic changes of the tool orientations and affects surface quality. The challenge is to strike a balance between the smooth tool orientations and suppression of chatter and SLE. To overcome the challenge, this paper presents a minimax optimization approach for planning tool orientations. The optimization objective is to obtain smooth tool orientations, by minimizing the maximum variation of the rotational angles between adjacent cutter locations, with constraints of chatter-free and SLE threshold. A dedicated designed ball-end milling experiment is conducted to validate the proposed approach. The work provides new insight into the tool path generation for ball-end milling of sculpture surface; also it would be helpful to decision-making for process parameters optimization in practical complex parts milling operations at shop floor.

Multitool and Multi-Axis Computer Numerically Controlled Accumulation for Fabricating Conformal Features on Curved Surfaces

2014 ◽  
Vol 136 (3) ◽  
Author(s):  
Yayue Pan ◽  
Chi Zhou ◽  
Yong Chen ◽  
Jouni Partanen
Keyword(s):  
Tool Path ◽  
Prototype System ◽  
Test Cases ◽  
Curved Surfaces ◽  
Engineering Systems ◽  
Multiple Test ◽  
Optical Cable ◽  
Spherical Surfaces ◽  
Computer Numerically Controlled ◽  
Planning Methods

In engineering systems, features such as textures or patterns on curved surfaces are common. In addition, such features, in many cases, are required to have shapes that are conformal to the underlying surfaces. To address the fabrication challenge in building such conformal features on curved surfaces, a newly developed additive manufacturing (AM) process named computer numerically controlled (CNC) accumulation is investigated by integrating multiple tools and multiple axis motions. Based on a fiber optical cable and a light source, a CNC accumulation tool can have multi-axis motion, which is beneficial in building conformal features on curved surfaces. To address high resolution requirement, the use of multiple accumulation tools with different curing sizes, powers, and shapes is explored. The tool path planning methods for given cylindrical and spherical surfaces are discussed. Multiple test cases have been performed based on a developed prototype system. The experimental results illustrate the capability of the newly developed AM process and its potential use in fabricating conformal features on given curved surfaces.

An Intelligent Optimization Approach of Feedrate Scheduling Based on Hybrid Simulation Models

2008 ◽  
Vol 392-394 ◽  
pp. 211-215
Author(s):  
Li Qiang Zhang ◽  
Yu Han Wang ◽  
Ming Chen
Keyword(s):  
Tool Path ◽  
Mechanistic Model ◽  
Geometric Model ◽  
Physical Models ◽  
Free Form ◽  
Optimization Approach ◽  
Machining Processes ◽  
Surface Machining ◽  
Feedrate Scheduling ◽  
Free Form Surface

In free-form surface machining, it is essential to optimize the feedrate in order to improve the machining efficiency. Conservative constant feedrate values have been mostly used since there was a lack of physical models and optimization tools for the machining processes. The overall goal of this research is the integration of geometric and mechanistic milling models for force prediction and feedrate scheduling for free-form surface machining. For each tool move a geometric model calculates the cutting geometry parameters, then a mechanistic model uses this information with the constraint force to calculate desired feedrates. The feedrate is written into the part program. When the integrated modeling approach was used, it was shown that the machining time can be decreased significantly along the tool path. Production time in machining propeller example was reduced to 35% compared to constant feedrate cases.

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