Skip to main content
SpringerLink
Log in

Cutter position optimization with tool runout for flank milling of non-developable ruled surfaces

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In the process of flank milling of a no-developable ruled surface, the non-expansible characteristic of the curved surface could negatively affect the surface finish of the mechanical parts. To be specific, tool runout is a factor that contributes to the decreased machining accuracy of the surface. In order to solve this problem, a cutter position optimization method based on tool runout is proposed in this paper. The coupling of the principle error and tool runout error was analyzed in the first place. The actual rotation radius of the cutter corresponding to the discrete points of the original cutter axis was then obtained through a method of measurement. The discrete points of the cutter axis in the case of tool runout were located by subdividing the surface continuously in the parameter field of the design surface. An error measurement function of the no-developable ruled surface in the case of the tool runout was constructed based on the new cutter axis position. Using a two-step optimization algorithm, the initial cutter position was finally calculated which was then further optimized through a single-point swing method with the factor of tool runout taken into consideration. The results show that, after incorporating the tool runout factor into the error optimization model, the average machining error is reduced by 25.6% and the overcutting rate is reduced by 18.8%. The surface finish of the mechanical parts is effectively improved.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28
Fig. 29
Fig. 30
Fig. 31
Fig. 32
Fig. 33
Fig. 34
Fig. 35
Fig. 36
Fig. 37
Fig. 39
Fig. 38
Fig. 40
Fig. 41
Fig. 42
Fig. 43
Fig. 44
Fig. 45
Fig. 46

Similar content being viewed by others

References

  1. Elber G, Fish R (1997) 5-axis freeform surface milling using piecewise ruled surface approximatio. J Manuf Sci Eng 119(3):383–387

    Article  Google Scholar 

  2. Han Z, Yang DCH, Chuang JJ (2001) Isophote-based ruled surface approximation of free-form surfaces and its application in NC machining. Int J Prod Res 39(9):1911–1930

    Article  Google Scholar 

  3. Xi G, Wu GK, Zheng JS (2008) Positioning algorithm for 5-axis machining of ruled surface based on radius an angle offset. Chinese J Mech Eng 44(4):92–96

    Article  Google Scholar 

  4. Hsin TH, Chih HC (2003) Improving optimization of tool path planning in 5-axis flank milling using advanced PSO algorithms. Robot Comput Integr Manuf 29:3–11

    Google Scholar 

  5. Liu XW (1995) Five-axis NC cylindrical milling of sculptured surfaces. Comput Aided Des 27(12):887–894

    Article  Google Scholar 

  6. Kong MB, Hu ZH, Li H, Chen XG, Zhang P (2008) New cutter-location optimization algorithm and error analysis for five-axis flank milling of integral impeller. Chinese J Mech Eng 44(11):276–282

    Article  Google Scholar 

  7. Chiou CJ (2004) Accurate tool position for five-axis ruled surface machining by swept envelope approach. Comput Aided Des 36(10):967–974

    Article  Google Scholar 

  8. Rrdonnet JM, Rubio W, Dessein G (1998) Flank milling of ruled surfaces: optimum positioning of the milling cutter and calculation of interference. Int J Adv Manuf Technol 14:459–465

    Article  Google Scholar 

  9. Yan T, Liu ZB, Wang XB, Fan Y (2015) Cutter location calculation for side milling of non-developable ruled surface based on four-point offset method. J Graphics 36(06):840–845

    Google Scholar 

  10. Bedi S, Mann S, Menzel C (2003) Flank milling with flat end milling cutters. Comput Aided Des 35(3):293–300

    Article  Google Scholar 

  11. Bo P, Bartoň M, Pottmann H (2017) Automatic fitting of conical envelopes to free-form surfaces for flank CNC machining. Comput Aided Des 91:84–94

  12. Menzel C, Bedi S, Mann S (2004) Triple tangent flank milling of ruled surfaces. Comput Aided Des 36(3):289–296

    Article  Google Scholar 

  13. Li CG, Bedi S, Mann S (2006) Flank milling of a ruled surface with conical tools—an optimization approach. Int J Adv Manuf Technol 29(11-12):1115–1124

    Article  Google Scholar 

  14. Yan CG, Liu Y, Cui YX (2015) Characteristic line method of cutter axis trajectory planning for no-developable ruled surface milling on the side of conical cutter. J Mech Eng 51(19):206–212

    Article  Google Scholar 

  15. Fu HJ, Liao W, Li YG (2013) Method for generation of guide rail for side milling of composite curved surface of aircraft structural parts. China Mech Eng 24(10):1306–1311

    Google Scholar 

  16. Calleja A, Bo P, González H, Bartoň M (2018) Highly accurate 5-axis flank CNC machining with conical tools. Int J Adv Manuf Technol 97(5-8):1605–1615

    Article  Google Scholar 

  17. Hu DF, Guo JW, Ren XZ (2017) Spatial linear regression analysis of arc CAM side milling tool rail. China Mech Eng 28(18):2249–2255

    Google Scholar 

  18. Senatore J, Landon Y, Rubio W (2008) Analytical estimation of error in flank milling of ruled surfaces. Comput Aided Des 40(5):595–603

    Article  Google Scholar 

  19. Hsieh HT, Chu CH (2012) Optimization of tool path planning in 5-axis flank milling of ruled surfaces with improved PSO. Int J Precis Eng Manuf 13(1):77–84

    Article  Google Scholar 

  20. Bo P, Bartoň M (2019) On initialization of milling paths for 5-axis flank CNC machining of free-form surfaces with general milling tools. Comput Aided Geom Des 71:30–42

  21. Arizmendi M, Fernández J, Gil A, Veiga F (2008) Effect of tool setting error on the topography of surfaces machined by peripheral milling. Int J Mach Tools Manuf 49(1):36–52

  22. Islam MN, Han UL, Cho DW (2008) Prediction and analysis of size tolerances achievable in peripheral end milling. Int J Adv Manuf Technol 39(1-2):129–141

    Article  Google Scholar 

  23. Zeng W, Jiang X, Blunt L (2009) Surface characterization-based tool wear monitoring in peripheral milling. Int J Adv Manuf Technol 40(3-4):226–233

    Article  Google Scholar 

  24. Qiang G, Sun Y, Guo D (2012) New mathematical method for the determination of cutter runout parameters in flat-end milling. Chinese J Mech Eng 25(5):947–952

    Article  Google Scholar 

  25. Kruger M, Denkena B (2013) Model-based identification of tool runout in end milling and estimation of surface roughness from measured cutting forces. Int J Adv Manuf Technol 65(5-8):1067–1080

    Article  Google Scholar 

  26. Artetxe E, Olver D, Lacalle LLD (2017) Solid subtraction model of the surface topography prediction in flank milling of thin-walled integral blade rotors (IBRs). Int J Adv Manuf Technol 90(1-4):741–752

    Article  Google Scholar 

  27. Yu ZH, Qin SF, Ding GF (2019) The precision prediction model of five-axis flank milling based on tool runout error was constructed. Comput Integr Manuf Syst 14(3):2096–4188

    Google Scholar 

  28. Kong S, Zhang LQ, Feng QQ (2020) Tool location optimization method for flank milling based on MWOA algorithm [J]. Comput Times 12:1–5

    Google Scholar 

Download references

Data and materials availability

The datasets generated and analyzed during the current study are available from the corresponding author on reasonable request.

Funding

The research is sponsored by the National Natural Science Foundation of China (No. 51775328).

Author information

Authors and Affiliations

  1. School of Mechanical and Automotive Engineering, Shanghai University of Engineering Science, Shanghai, 201620, People’s Republic of China

    Sen Kong, Yecui Yan, Liqiang Zhang & Qianqian Feng

Authors
  1. Sen Kong
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yecui Yan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Liqiang Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Qianqian Feng
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Sen Kong and Yecui Yan contributed to the conceptualization, writing, and editing. Liqiang Zhang contributed to the methodology. Qianqian Feng provided resources and performed experiment verification.

Corresponding author

Correspondence to Liqiang Zhang.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

Yes, consent to participate from all the authors.

Consent for publication

Yes, consent to publish from all the authors.

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Kong, S., Yan, Y., Zhang, L. et al. Cutter position optimization with tool runout for flank milling of non-developable ruled surfaces. Int J Adv Manuf Technol 115, 2747–2763 (2021). https://doi.org/10.1007/s00170-021-07270-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-07270-5

Keywords

Search

Navigation