PSO-Based Feedrate Optimization Algorithm for Five-Axis Machining with Constraint of Contour Error

Feedrate has a great influence on contour error in five-axis machining. Accordingly, it is of great significance to plan the time-optimal feedrate curve considering the contour error constraint to achieve high-accuracy and high-efficiency machining. Aiming at improving the error control accuracy of model linearization loss and optimizing the machining time, the PSO-based feedrate optimization algorithm for five-axis machining with constraint of contour error is proposed in this paper. Firstly, the relationship between parametric feedrate and contour error constraint is clarified that provides a model basis for accurately controlling contour error by optimizing the feedrate curve. Then, the feedrate optimization model, which takes the control vertices of the feedrate curve expressed by B-spline as the decision variables and minimizes the machining time as the optimization objective, is established. Subsequently, to overcome the shortcomings of low accuracy and low efficiency caused by single optimization of global control vertices, the group search particle swarm optimization (GSPSO) algorithm based on window movement is adopted to optimize the feedrate curve in segments. Finally, the effectiveness of the proposed feedrate optimization algorithm is validated by three typical test toolpaths on an open double-turntable five-axis machine tool. In light of the experiment, the proposed algorithm is able to fully release the potential of the machine tools while accurately controlling the contour error of the cutter tip and cutter orientation.

Automated summary

The feedrate has a significant impact on contour error in five-axis machining. Therefore, it is important to plan a time-optimal feedrate curve considering the contour error constraint to achieve high-accuracy and high-efficiency machining. This paper proposes a PSO-based feedrate optimization algorithm for five-axis machining with the constraint of contour error, aiming to improve the error control accuracy and optimize the machining time. The effectiveness of the algorithm is validated through experiments on an open double-turntable five-axis machine tool, demonstrating accurate control of contour error while fully utilizing the potential of the machine tools.