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Postprocessor algorithm and feedrate optimization for nine-axis milling machine tool with twin cutters

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Abstract

Twin-tool synchronous milling is a new method for blade machining which can improve the machining efficiency obviously. It can be realized on a nine-axis machine tool with two cutters. However, the kinematic analysis and the feedrate planning are more difficult, due to the more complex structure than the traditional five-axis machine tool. In this paper, an efficient postprocessor algorithm is developed and feedrate optimization method is proposed to realize twin-tool synchronous milling. Based on a brief structure and kinematic chain analysis, the generalized kinematic model is built. Considering the characteristics that the A-axis is shared by two cutters in the nine-axis machine tool, the mathematical formulas of the motion coordinates and rotary angles are derived, which can simultaneously transform the location and orientation vectors of the two cutters into numerically controlled (NC) codes. Meanwhile, the feedrate is planned to maintain the simultaneous cutting with the two cutters, even though the displacements between adjacent cutting contact points on the opposite blade surfaces are unequal. Then, the feedrate optimization strategy is proposed to guarantee the continuity of the cutting speed; the saturation limit for each servo motor is also considered. Furthermore, the NC codes for machining a typical turbine blade are generated with the developed postprocessor algorithm, then the velocity and acceleration of each axis at different cutter-contact-point are calculated. The validity is demonstrated with simulation and experiments on a self-developed nine-axis machine tool.

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Funding

This work is financially supported by the Projects of National Natural Science Foundation of China (51605373, 51235009) and the Major Project of High-end CNC Machine Tool and Basic Manufacturing Equipment of China (2018ZX04004001).

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Authors and Affiliations

  1. State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Room A315 West Building 5, 99# Yanxiang Road, Yanta District, Xi’an, 710054, Shaanxi Province, China

    Dongdong Song, Fei Xue, Jun Zhang, Cunfan Zou, Wanhua Zhao & Bingheng Lu

  2. School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, 710049, Shaanxi Province, China

    Dongdong Song, Fei Xue, Jun Zhang, Cunfan Zou, Wanhua Zhao & Bingheng Lu

Authors
  1. Dongdong Song
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  2. Fei Xue
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  3. Jun Zhang
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  4. Cunfan Zou
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  5. Wanhua Zhao
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  6. Bingheng Lu
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Correspondence to Fei Xue or Wanhua Zhao.

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Song, D., Xue, F., Zhang, J. et al. Postprocessor algorithm and feedrate optimization for nine-axis milling machine tool with twin cutters. Int J Adv Manuf Technol 103, 1745–1757 (2019). https://doi.org/10.1007/s00170-019-03661-x

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  • DOI: https://doi.org/10.1007/s00170-019-03661-x

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