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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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
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Abstract	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.
AbstractList	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.
Author	Liu, Zhifeng Zhao, Pengrui Cao, Zirui Li, Zhixiong
Author_xml	– sequence: 1 givenname: Pengrui surname: Zhao fullname: Zhao, Pengrui organization: Institute of Advanced Manufacturing and Intelligent Technology, Beijing University of Technology, Beijing Key Laboratory of Advanced Manufacturing Technology, Beijing University of Technology – sequence: 2 givenname: Zhifeng orcidid: 0000-0003-1979-5248 surname: Liu fullname: Liu, Zhifeng email: lzf@bjut.edu.cn organization: Mechanical Industry Key Laboratory of Heavy Machine Tool Digital Design and Testing, Beijing University of Technology, Key Laboratory of CNC Equipment Reliability, Ministry of Education, School of Mechanical and Aerospace Engineering, Jilin University – sequence: 3 givenname: Zhixiong surname: Li fullname: Li, Zhixiong organization: Institute of Advanced Manufacturing and Intelligent Technology, Beijing University of Technology, Mechanical Industry Key Laboratory of Heavy Machine Tool Digital Design and Testing, Beijing University of Technology – sequence: 4 givenname: Zirui surname: Cao fullname: Cao, Zirui organization: Beijing Key Laboratory of Advanced Manufacturing Technology, Beijing University of Technology, Mechanical Industry Key Laboratory of Heavy Machine Tool Digital Design and Testing, Beijing University of Technology
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Cites_doi	10.1109/ACCESS.2018.2848938 10.1080/0020754031000153342 10.1007/978-1-84800-380-4 10.1016/S0890-6955(03)00107-X 10.3901/JME.2008.10.009 10.1016/S0010-4485(02)00077-5 10.1080/00207540802570685 10.1016/j.cad.2014.08.010 10.1007/s00170-016-8356-3 10.1016/0924-0136(93)90194-B 10.1016/j.cad.2011.09.005 10.1016/j.ijmachtools.2005.07.036 10.1007/s00170-018-2478-8 10.1016/j.cad.2007.04.003 10.1115/1.4031678 10.1016/j.cad.2008.08.006 10.1109/ROBOT.1997.614307 10.1145/3476576.3476769
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SubjectTerms	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
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Title	Research on tool axis vector optimization when face milling complex surfaces
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