Tool Orientation Planning in Milling With Process Dynamic Constraints: A Minimax Optimization Approach
Tool Orientation Planning in Milling With Process Dynamic Constraints: A Minimax Optimization Approach
复制标题
具有过程动态约束的铣削中的刀具方向规划：极小极大优化方法
DOI：
10.1115/1.4040872
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发表时间：
2018-07
期刊：
影响因子：
--
通讯作者：
Ding Han
中科院分区：
文献类型：
--
作者：
Huang Tao;Zhang Xiao-Ming;Leopold Juergen;Ding Han
在五轴联动铣削加工中，商业软件生成的刀具轨迹很少考虑加工过程的动力学特性。忽视过程动力学可能导致铣削颤振，这会导致过切、刀具快速磨损等，从而损坏工件表面并缩短工具寿命。这促使我们在刀具轨迹生成中考虑动态约束。五轴球头铣刀铣削过程中，由于刀具-工件浸入面积和切削力的变化，刀具方向的变化会影响颤振稳定性和表面定位误差，从而为抑制颤振和表面定位误差提供了一种灵活可行的方法。然而，为了抑制颤振和系统误差而调整刀具方向可能会导致刀具方向发生剧烈变化并影响表面质量。挑战是在平滑的刀具方向和抑制颤振和SLE之间取得平衡。为了克服这一挑战，本文提出了一种极小极大优化方法规划刀具方向。优化目标是在无颤振和SLE阈值的约束下，通过最小化相邻刀具位置之间的旋转角的最大变化来获得平滑的刀具取向。设计了一个专用的球头铣削实验，以验证所提出的方法。该研究为球头铣刀铣削雕塑曲面的刀具轨迹生成提供了新的思路，同时也为复杂零件的铣削加工过程中的工艺参数优化提供了决策依据。
In five-axis milling process, the tool path generated by a commercial software seldom takes the dynamics of the machining process into account. The neglect of process dynamics may lead to milling chatter, which causes overcut, quick tool wear, etc., and thus damages workpiece surface and shortens tool life. This motivates us to consider dynamic constraints in the tool path generation. Tool orientation variations in five-axis ball-end milling influence chatter stability and surface location error (SLE) due to the varying tool-workpiece immersion area and cutting force, which inversely provides us a feasible and flexible way to suppress chatter and SLE. However, tool orientations adjustment for suppression of chatter and SLE may cause drastic changes of the tool orientations and affects surface quality. The challenge is to strike a balance between the smooth tool orientations and suppression of chatter and SLE. To overcome the challenge, this paper presents a minimax optimization approach for planning tool orientations. The optimization objective is to obtain smooth tool orientations, by minimizing the maximum variation of the rotational angles between adjacent cutter locations, with constraints of chatter-free and SLE threshold. A dedicated designed ball-end milling experiment is conducted to validate the proposed approach. The work provides new insight into the tool path generation for ball-end milling of sculpture surface; also it would be helpful to decision-making for process parameters optimization in practical complex parts milling operations at shop floor.
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影响因子：
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