Globally optimal tool paths for sculptured surfaces with emphasis to machining error and cutting posture smoothness

Abstract

Global optimization for manufacturing problems is mandatory for obtaining versatile benefits to facilitate modern industry. This paper deals with an original approach of globally optimizing tool paths to CNC-machine sculptured surfaces. The approach entails the development of a fully automated manufacturing software interface integrated by a non-conventional genetic/evolutionary algorithm to enable intelligent machining. These attributes have been built using already existing practical machining modelling tools such as CAM systems so as to deliver a truly viable computeraided manufacturing solution. Since global optimization is heavily based in the formulation of the problem, emphasis has been given to the definition of optimization criteria as crucial elements for representing performance. The criteria involve the machining error as a combined effect of chord error and scallop height, the tool path smoothness and productivity. Experiments have been designed considering several benchmark sculptured surfaces as well as tool path parameters to validate the aforementioned criteria. The new approach was implemented to another sculptured surface which has been extensively tested by previous research works. Results were compared to those available in the literature and it was found that the proposed approach can indeed constitute a promising and trustworthy technique for the global optimization of sculptured surface CNC tool paths.

A Multi-Scale Tool Orientation Generation Method for Freeform Surface Machining with Bull-Nose Tool

“…The optimization algorithm could minimize the angular acceleration of the rotational axis. Fountas et al [ 55 ] proposed a tool path global optimization method that uses intelligent algorithms to minimize machining errors, tool orientation smoothness, and production efficiency. Lu et al [ 56 ] provided a five-axis side milling tool path generation method to smooth the rotational axis for impeller parts.…”

NURBS Interpolation Algorithm to Minimize Chord Error in 5-Axis CNC Milling Operations of Turbine Blades

“…To provide feed rate scheduling system with High-speed estimation of a micro-line tool path with a chord error restriction, advanced B-spline fitting scheme with abilities of knot vector and control points movement along machining paths is presented by Bi et al [7]. To decrease chord errors during milling operations of sculptured surfaces, optimized cutting tool paths by using non-conventional genetic algorithm is developed by Fountas et al [8]. To decrease chord length deviation during machining operations of aero-engine thin-walled blade, advanced method of machined blade profile errors is proposed by Feng et al [9].…”

Cutting Tool Path Modification to Uniform Scallop‐Height in Three-Axis Milling Operations

“…Advanced method of e cient iso-scallop cutting tool path is presented by Liu et al [10] to increase surface quality of machined parts during three-axis scattered cloud machining operations. To increase surface quality by providing uniform scallop during machining operations of sculptured surfaces, optimized cutting tool paths is presented by Fountas et al [11]. To achieve the uniform scallop height and increase surface quality of during machining operations of free form surfaces, advanced barrel cutting tool design and cutting tool path planning system is presented by Luo et al [12].…”