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Tool orientation optimization method based on the best curvature matching

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Abstract

Parts with free-form surfaces exhibit a complex structure and are difficult to process. The processing quality of such surfaces determines the performance and service life of the product. Tool orientation is vital for ensuring five-axis computer numerical control (CNC) machining efficiency and accuracy. Unlike the ball-end tool, the bull-nose tool (the bull-nose cutter) can adapt to the curvature change of the machined free-form surface and achieve superior machining quality because of its special geometry. A novel tool orientation optimization method based on the best curvature matching was used to fully exploit the advantages of the bull-nose tool. First, the relationship between the evaluated scallop height and the normal evaluation curvature was obtained for an arbitrary CC point. A curvature matching model was developed to evaluate the degree of matching between the tool and workpiece on the evaluation plane. Subsequently, based on the analysis of the effect of the tool type and orientation on curvature matching, a tool orientation optimization method based on the best curvature matching was proposed. Finally, the proposed optimization method was verified by performing a machining experiment of the free-form surface. The results revealed that the proposed method reduced the scallop height by 68.62%. The obtained results revealed that the proposed method could improve machining quality. Thus, the method exhibits high potential in engineering applications.

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© 5-axis measurement system employed to measure the machined surface

Fig. 19

© 5-axis measurement system on each surface. (a) Surface #1, (b) Surface #2, (c) Surface #3

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Funding

This work received financial support from the National Natural Science Foundations of China (Grant Nos. 51775445 and 52175435), Defense Industrial Technology Development Program (No. XXXX2018213A001), and Shaanxi Province Major R&D Project (No. 2021ZDLGY03-07).

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Authors and Affiliations

  1. Department of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, China

    Jieshi Dong, Zhiyong Chang, Peng Chen, Jinming He & Neng Wan

  2. Institute for Aero-Engine Smart Assembly of Shaanxi Province, Xi’an, 710072, Shaanxi, China

    Jieshi Dong, Zhiyong Chang, Peng Chen, Jinming He & Neng Wan

Authors
  1. Jieshi Dong
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  2. Zhiyong Chang
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  3. Peng Chen
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  4. Jinming He
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  5. Neng Wan
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Contributions

All authors contributed to the design and implementation of the concept. Jieshi Dong: conceptualization, methodology, experimental design, writing-original draft preparation; Peng Chen, Jinming He, and Neng Wan: investigation, experiment, data processing, and analysis; Zhiyong Chang: writing review and editing. All authors connected on previous versions of the manuscript and have read and approved the final manuscript.

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Correspondence to Zhiyong Chang.

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Dong, J., Chang, Z., Chen, P. et al. Tool orientation optimization method based on the best curvature matching. Int J Adv Manuf Technol 124, 127–142 (2023). https://doi.org/10.1007/s00170-022-10526-3

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