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Research on tool diameter and processing width optimization for highly efficient machining of complex surfaces constrained by machining interference surface

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Abstract

During five-axis cutting, the unreasonable selection of the tool’s diameter and processing width will greatly affect processing efficiency. However, the existing tool’s diameter and processing width values avoid local over-cutting, which is conservative. Therefore, a calculation method of optimal cutting diameter and processing width based on machining interference surface with flat-end cutter as the research object is proposed in this paper. First, the offset surface of discrete points is constructed as the machining interference surface based on the implicit surface theory. The surface offset is the maximum allowable machining error. Then, according to the Dupin indicatrix line between the tool and the machining surface, sufficient and necessary conditions for the local malleability of the flat-end cutter are obtained. Based on the constructed machining interference surface, the optimal diameter of the tool is calculated via the effective cutting profile curve of the tool at the interference surface. Next, the next cutter contact point is obtained by intersecting the tangent line between the cutter contact point and the upper or lower limit surface of the machining interference surface and the cutting path curve. The processing width is calculated according to the distance between the two adjacent cutter contact points. Finally, the proposed algorithm is verified by CAM software simulation and experiments by taking a complex surface as an example. The experimental results show that the optimization algorithm of the tool’s diameter and bandwidth under the constraint of machining interference surface can shorten the machining time and obtain higher machining efficiency in the NC machining of complex surfaces.

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Data Availability

The datasets used or analyzed during this study are available from the corresponding author upon reasonable request.

Code availability

Not applicable.

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Funding

This research is supported by the National Natural Science Foundation of China (No. 51975019).

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Authors and Affiliations

  1. Institute of Advanced Manufacturing and Intelligent Technology, Beijing University of Technology, Beijing, 100124, China

    Pengrui Zhao & Zhixiong Li

  2. Beijing Key Laboratory of Advanced Manufacturing Technology, Beijing University of Technology, Beijing, 100124, China

    Pengrui Zhao & Dong Li

  3. Mechanical Industry Key Laboratory of Heavy Machine Tool Digital Design and Testing, Beijing University of Technology, Beijing, 100124, China

    Zhifeng Liu, Zhixiong Li & Dong Li

  4. Key Laboratory of CNC Equipment Reliability, Ministry of Education, School of Mechanical and Aerospace Engineering, Jilin University, Changchun, 130015, China

    Zhifeng Liu

Authors
  1. Pengrui Zhao
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  2. Zhifeng Liu
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  3. Zhixiong Li
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  4. Dong Li
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Contributions

All authors contributed to the study conception and design. Pengrui Zhao and Zhifeng Liu performed material preparation, data collection, and analysis. The first draft of the manuscript was written by Pengrui Zhao, Zhifeng Liu, and Zhixiong Li. All authors commented on previous versions of the manuscript. Dong Li is responsible for data. All authors read and approved the final manuscript.

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Correspondence to Zhifeng Liu.

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Zhao, P., Liu, Z., Li, Z. et al. Research on tool diameter and processing width optimization for highly efficient machining of complex surfaces constrained by machining interference surface. Int J Adv Manuf Technol 128, 5061–5080 (2023). https://doi.org/10.1007/s00170-023-11900-5

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  • DOI: https://doi.org/10.1007/s00170-023-11900-5

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