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Adaptive milling for contours on deformed surface based on on-machine measurement and optimized parallel projection

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Abstract

Machining contours on a large thin-walled part is a difficult task due to inevitable deformation of the actual part. The deformation of the contour can significantly influence the rigidity of the thin-walled part; thus, it is of importance to minimize the deformation of the contour compared with the design contour. This paper proposes a novel method to adaptively calculate the optimal contour on the deformed surface based on optimized parallel projection. The geometry data of free-form surface is obtained by on-machine measurement (OMM), and then, the actual surface is reconstructed using the measurement data. The reconstructed surface is matched with the design surface, and then, the design contour was projected onto the reconstructed surface to obtain the locating contour. The iterative nearest point (ICP) algorithm is used to adjust the design contour to match the locating contour. Finally, the projection direction is optimized to minimize contour deformation, and the adjusted contour is projected onto the reconstructed surface along the optimal direction to obtain the new contour. The effectiveness of this method is verified by machining and measuring experiments.

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Funding

This work was supported by the National Natural Science Foundation of China (Nos. 52075337), the State Key Laboratory of Mechanical System and Vibration (No. MSVZD202113), and the Shanghai Pujiang Program (No. 2020PJD024).

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Authors and Affiliations

  1. School of Power and Mechanical Engineering, Wuhan University, Wuhan, 430072, China

    Bowen Yi, Xiaosun Wang & Shijing Wu

  2. State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Rui Li & Nuodi Huang

  3. Sichuan Aerospace Changzheng Equipment Manufacturing Co., Ltd, Chengdu, 610100, China

    Weidong Li

Authors
  1. Bowen Yi
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  2. Rui Li
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  3. Weidong Li
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  4. Xiaosun Wang
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  5. Shijing Wu
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  6. Nuodi Huang
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Correspondence to Nuodi Huang.

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Yi, B., Li, R., Li, W. et al. Adaptive milling for contours on deformed surface based on on-machine measurement and optimized parallel projection. Int J Adv Manuf Technol 126, 443–452 (2023). https://doi.org/10.1007/s00170-023-11141-6

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  • DOI: https://doi.org/10.1007/s00170-023-11141-6

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