Advertisement

Optimal CNC plunge cutter selection and tool path generation for multi-axis roughing free-form surface impeller channel

  • F. Y. Han
  • D. H. Zhang
  • M. Luo
  • B. H. Wu
ORIGINAL ARTICLE

Abstract

Plunge milling is the most effective way for rough machining of impeller parts, but previous research had not considered the optimization of plunge cutter selection and tool path. In this paper, a new method for optimizing the plunge cutter selection and tool path generation in multi-axis plunge milling of free-form surface impeller channel is proposed in order to improve the efficiency in rough machining. Firstly, in the case of fixing a rotation axis at a certain angle in five-axis machine, a mathematical representation is formulated for the geometric model of the cutter interfering the impeller, and an optimization model of the cutter size is established at a cutter contact point on the impeller channel surface, so the largest tool could be determined. Secondly, by analyzing the machine tool movement characteristics, the geometric constraint model of the plunge tool path which relative to the largest tool, step distance, and row space is established, and a tool orientation calculation method of impeller channel machining is given, and then, the plunge tool path and tool orientation could be obtained. Finally, the generated tool path and tool orientation are simulated and verified in practical processing. Simulation and experimental result shows that the rough machining efficiency of the impeller part is improved up to 40 % with this method.

Keywords

Impeller channel Plunge milling Tool path Tool orientation The largest tool 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    El-Midany TT, Elkeran A, Tawfik H (2006) Optimal CNC plunge selection and toolpoint generation for roughing sculptured surfaces cavity. J Manuf Sci Eng 128(4):1025–1029CrossRefGoogle Scholar
  2. 2.
    Tawfik H(2009) A new algorithm to calculate the optimal inclination angle for filling of plunge-milling. Int J CAD/CAM 6(1)Google Scholar
  3. 3.
    Wakaoka S, Yamane Y, Sekiya K, Narutaki N (2002) High-speed and high-accuracy plunge cutting for vertical walls. Mate Process Technol 127(2):246–250CrossRefGoogle Scholar
  4. 4.
    Gan WF, Fu JZ, Lin ZW, Li YC (2010) Tool-path planning based on iso-scallop for plunge milling in pocket walls manufacture. Mech Autom Control Eng (MACE) 26–28:3434–3437Google Scholar
  5. 5.
    Liang Q, Wang YZ (2011) A new rough machining approach for a ruled surface impeller. Appl Mech Mater 79(53):53–58CrossRefGoogle Scholar
  6. 6.
    Hu CG, Zhang DH, Ren JX (2007) Research on the plunge milling of blisk tunnel. China Mech Eng 18(2):153–155, in ChineseGoogle Scholar
  7. 7.
    Shan CW, Zhang DH, Ren JX, Hu CG (2006) Research on the plunge milling techniques for open blisks. Mater Sci Forum: Trans Tech Publ Switzerland 532–533:193–196CrossRefGoogle Scholar
  8. 8.
    Ren JX, Yao CF, Zhang DH, Xue YL, Liang YS (2009) Research on tool path planning method of four-axis high-efficiency slot plunge milling for open blisk. Int J Adv Manuf Technol 45(1–2):101–109CrossRefGoogle Scholar
  9. 9.
    Nadjakova I, McMains S (2004) Finding an optimal set of cutter radii for 2D pocket machining. In: Proceedings of 2004 ASME international mechanical engineering congress and RD & D expo. IMECE 62224:2004Google Scholar
  10. 10.
    Elber G, Cohen E, Drake S (2005) MATHSM: medial axis transform toward high speed machining of pockets. Comput Aided Des 37(2):241–250CrossRefGoogle Scholar
  11. 11.
    Chen ZC, Zhang HD (2009) Optimal cutter size determination for 21/2-axis finish machining of NURBS profile parts. Int J Prod Res 47(22):6279–6293CrossRefGoogle Scholar
  12. 12.
    Chen ZC, Liu G (2009) An intelligent approach to multiple cutters of maximum sizes for three-axis milling of sculptured surface parts. J Manuf Sci Eng 131:014501–014505CrossRefGoogle Scholar
  13. 13.
    Yang ZX, Joneja A, Zhu SM (2001) Recognizing generalized pockets for optimizing machining time in process planning—part 2. Int J Prod Res 39(16):3601–3621CrossRefzbMATHGoogle Scholar
  14. 14.
    Joneja A, Yuen WF, Lee YS (2003) Greedy tool heuristic approach to rough milling of complex shaped pockets. IIE Trans 35(10):953–963CrossRefGoogle Scholar
  15. 15.
    Yao ZY, Gupta SK, Nau DS (2001) A geometric algorithm for finding the largest milling cutter. J Manuf Process 3(1):1–16CrossRefGoogle Scholar
  16. 16.
    Yao ZY, Gupta SK, Nau DS (2003) Algorithm for selecting cutters in multi-part milling problems. Comput Aided Des 35(9):825–839CrossRefGoogle Scholar
  17. 17.
    Zhang YJ, Li YL (2007) New approach to selecting multiple tools for milling 2.5-D pockets. Proc IEEE Int Conf Mechtron Autom 5:2320–2325Google Scholar
  18. 18.
    Narayanaswami R, Choi Y (2001) NC machining of freeform pockets with arbitrary wall geometry using a grid-based navigation approach. Int J Adv Manuf Technol 18(10):708–716CrossRefGoogle Scholar
  19. 19.
    D’Souza RM, Sequin C, Wright PK (2004) Automated tool sequence selection for 3-axis machining of free-form pockets. Comput Aided Des 36(7):595–605CrossRefGoogle Scholar
  20. 20.
    Lin ZW, Shen HY, Gan WF, Fu JZ (2012) Approximate tool posture collision-free area generation for five-axis CNC finishing process using admissible area interpolation. Int J Adv Manuf Technol 62(9–12):1191–1203Google Scholar
  21. 21.
    Li LL, Zhang YF, Li HY, Geng L (2011) Generating tool-path with smooth posture change for five-axis sculptured surface machining based on cutter’s accessibility map. Int J Adv Manuf Technol 53(5–8):699–709CrossRefGoogle Scholar
  22. 22.
    Roy D (2005) Study on the configuration space based algorithmic path planning of industrial robots in an unstructured congested three-dimensional space: an approach using visibility map. J Intell Robot Syst 43(2–4):111–145CrossRefGoogle Scholar
  23. 23.
    Sandvik Coromant (2006) “High productive milling” user’s guide. http://www.sandvik.coromant.com

Copyright information

© Springer-Verlag London 2014

Authors and Affiliations

  1. 1.Key Laboratory of Contemporary Design and Integrated Manufacturing Technology (Northwestern Polytechnical University)Ministry of EducationXi’anChina

Personalised recommendations