Optimization of the cutter size and tool orientation for reaching the critical state with multi-constraints in deep and
- PDF / 6,352,234 Bytes
- 33 Pages / 595.276 x 790.866 pts Page_size
- 62 Downloads / 117 Views
ORIGINAL ARTICLE
Optimization of the cutter size and tool orientation for reaching the critical state with multi-constraints in deep and narrow channel parts machining Wenbo Zhang 1 & Junxue Ren 1 & Yongshou Liang 1 Received: 9 December 2019 / Accepted: 17 July 2020 / Published online: 1 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Increasing the cutter size to enhance its stiffness is of great significance for improving the machining efficiency and precision of deep and narrow channel parts. In this paper, the concept of cutter size critical sphere (CSCS) is presented, which is a specified sphere and tangent to several geometric constraints of tool accessible regions. With this concept, the complex multi-constraints of the workpiece can be transformed into several simple but precise geometric conditions to optimize the size and tool orientation of a conical cutter. The conical cutter generated by CSCS can reach a critical state with multi-constraints simultaneously. Firstly, the mathematical principle of the conical cutter generated by a cylindrical cutter is deduced based on the motion envelope theory. Secondly, the concept of CSCS is proposed based on the deduced mathematical principle and the calculation method of the CSCS with the general situation is provided. Thirdly, the CSCS with special situations is discussed and the calculation method is proposed. Fourthly, the mathematical model and solving algorithm for the max-size CSCS is given. The solving algorithm is designed based on the 3D Medial Axis Transformation (3D MAT) theory. Finally, the proposed method is verified by three simulation experiments and a comparison experiment. The results show that the proposed method can efficiently and accurately calculate the max size and tool orientation of the conical cutter simultaneously. The optimized conical cutter can be tangent to the multi-constraints of the workpiece but do no interfer with them. Keywords Five-axis machining . Cutter size critical sphere . Critical state with multi-constraints . Simultaneous optimization . Max-size cutter . Tool orientation
1 Introduction In order to reduce weight and improve work efficiency, the fan blade of the new generation of aeroengine relies on more complex design structures. This brings new challenges to five-axis machining. For example, the leading edge of the fan blades uses a structural reinforcement part for improving the ability of the impact resistance, which is made of titanium alloy. As shown in Fig. 1, it is a deep and narrow channel part and belongs to an untypical kind of complex channel parts. Due to the structural characteristics of the part, the machining cutter would have a very large length/diameter ratio which is
* Junxue Ren [email protected] 1
School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an 710072, China
usually more than 10:1. As a result, the cutter stiffness is too weak to avoid deformation when machining the surface near the bottom of the channel. This will bring problem
Data Loading...
