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Cutter partition-based tool orientation optimization for gouge avoidance in five-axis machining

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Abstract

This paper presents a cutter partition-based tool orientation optimization algorithm that can identify and eliminate both local and rear gouging in five-axis machining. This algorithm is developed to generate smooth gouge-free tool paths for arbitrary free-form surfaces machined by general Automatically Programmed Tools (APT) cutters. The algorithm involves an iterative process of cutter projection to compute the gouge-free cutter positions. During each iteration, the cutter partition method is used to classify the cutting portion of the cutter, which in turn determines the gouging condition. Based on the classification, the algorithm applies an optimal gouge-avoidance strategy to minimize the size of tool orientation and position changes. The proposed algorithm can handle the combination of local and rear gouging (either separately or simultaneously), guarantee front edge cutting (avoiding damage to the cutter and surface), ensure a safety clearance between the rear edge of the cutter and the machined surface, and achieve minimal interruption to tool orientation and position from gouge avoidance. Simulation and cutting experiments confirm the effectiveness of the proposed algorithm.

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Acknowledgments

We acknowledge the support of Dongfang Turbine Co., Ltd. for the machining experiments, and the help of Lixiong Gan, Fan Yang, and Changya Yan.

Funding

The authors gratefully acknowledge the support of the National Science and Technology Major Project of the Ministry of Science and Technology of China (2013ZX04007-041).

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Authors and Affiliations

  1. Huazhong University of Science and Technology, Wuhan, China

    Xiyan Li, Chen-Han Lee, Pengcheng Hu, Yang Zhang & Fangzhao Yang

  2. Wuhan Institute of Technology, Wuhan, China

    Chen-Han Lee

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  1. Xiyan Li
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  4. Yang Zhang
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Correspondence to Chen-Han Lee.

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Li, X., Lee, CH., Hu, P. et al. Cutter partition-based tool orientation optimization for gouge avoidance in five-axis machining. Int J Adv Manuf Technol 95, 2041–2057 (2018). https://doi.org/10.1007/s00170-017-1263-4

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  • DOI: https://doi.org/10.1007/s00170-017-1263-4

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