期刊
COMPUTER-AIDED DESIGN
卷 151, 期 -, 页码 -出版社
ELSEVIER SCI LTD
DOI: 10.1016/j.cad.2022.103334
关键词
5-axis CNC machining; Trochoidal milling; Custom-shaped tools; Roughing operations; Tangential movability; Free-form shape manufacturing
资金
- National Natural Science Foundation of China [62072139]
- Spanish Ministry of Science, Innovation and Universities [PID20 19-104488RB-I00, SEV-20 17-0718]
- European Union [8620 25]
- Ramon y Cajal fellowship [RYC-2017-22649]
A novel method for trochoidal flank milling of 3D cavities bounded by free-form surfaces is introduced, which incorporates the shape of the tool into the optimization cycle and ensures high precision quality. It also supports multi-layer approach and maximizes the material removal rate while meeting machining tolerances.
A novel method for trochoidal flank milling of 3D cavities bounded by free-form surfaces is proposed. Existing 3D trochoidal milling methods use on-market milling tools whose shape is typically cylindrical or conical, and is therefore not well-suited for meeting fine milling tolerances required for finishing of benchmark free-form surfaces like blades or blisks. In contrast, our variational framework incorporates the shape of the tool into the optimization cycle and looks not only for the trochoidal milling paths, but also for the shape of the tool itself. High precision quality is ensured by firstly designing flank milling paths for the side surfaces that delimit the motion space, in which the trochoidal milling paths are further computed. Additionally, the material removal rate is maximized with the cutter-workpiece engagement being constrained under a given tolerance. Our framework also supports multi-layer approach that is necessary to handle deep cavities. The ability and efficacy of the proposed method are demonstrated by several industrial benchmarks, showing that our approach meets fine machining tolerances using only a few trochoidal paths. (C) 2022 Elsevier Ltd. All rights reserved.
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