Research on tool axis vector optimization when face milling complex surfaces

In 5-axis machining, the existing tool’s axis vector optimization methods are limited since they only consider the global collision between the tool and the workpiece while aiming at the ball-nosed cutter. A multi-factor vector optimization method for the face milling cutter shaft is proposed to sol...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology Vol. 128; no. 11-12; pp. 5081 - 5099
Main Authors: Zhao, Pengrui, Liu, Zhifeng, Li, Zhixiong, Cao, Zirui
Format: Journal Article
Language:English
Published: London Springer London 01.10.2023
Springer Nature B.V
Subjects:
Algorithms
Angular speed
Angular velocity
CAE) and Design
Computer-Aided Engineering (CAD
Cutting force
Cutting parameters
End milling
End milling cutters
Engineering
Face milling
Face milling cutters
Industrial and Production Engineering
Machine tools
Mechanical Engineering
Media Management
Optimization
Optimization models
Original Article
Rotating machinery
Rotating shafts
Workpieces
Cutting force modeling
Tool axis vector optimization
Spatial global collision detection algorithm
Dijkstra algorithm
ISSN:0268-3768, 1433-3015
Online Access:Get full text
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Summary:In 5-axis machining, the existing tool’s axis vector optimization methods are limited since they only consider the global collision between the tool and the workpiece while aiming at the ball-nosed cutter. A multi-factor vector optimization method for the face milling cutter shaft is proposed to solve this problem. This method comprehensively considers machining global collision, cutting force, the angular displacement of a rotating shaft, and angular speed. An improved global collision detection method of cutter axis vector based on the NURBS surface principle is developed, and a global collision detection algorithm is employed to determine the cutter machining global collision. The relationship model between the end-milling cutter axis vector and cutting force variation is established to optimize the cutting force. In addition, an optimization model of angular displacement and velocity of the machine tool’s rotating axis is proposed based on Dijkstra optimal path algorithm. The CAM software simulation and experimental validation are conducted using a large propeller with a complex surface. The tool’s axis vector optimization algorithm is applied to the propeller results. Comparing the tool’s axis vector optimization results to those obtained without optimization, it is discovered that the surface workpiece’s machining quality has significantly increased.
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content type line 14
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-023-12031-7