Tool Orientation Optimization Method Based on Kinematics Constraints of the Machine Tool in Multi-axis Machining with a Ball-end Cutter

doi:10.3901/JME.2015.23.160

Abstract

Abstract: In order to solve the problem of the poor machining quality of the leading and trailing edge surface of the aero engine blade, a tool orientation optimization method based on the kinematics constraints of the machine tool in multi-axis machining with a ball-end cutter is presented. A relation equation between the design variables of tool position and cutter location (CL) data is established, and a coordinate transformation equation between CL data and rotary axes of the machine tool is established. From the above two equations, a relation equation between the design variables of tool position and rotary axes of the machine tool is derived. Through solving the above relation equation, formulas for calculating tool position and tool orientation during the machining of sculptured surfaces with a ball-end cutter are derived. On this basis, a tool orientation optimization method and a tool path generation method for multi-axis machining with a ball-end cutter is presented. Besides, analyze the influence of the proposed method and Sturz method on rotary axes of the machine tool. Tool paths of the leading edge surface of an aero engine blade are generated by the proposed method and the Sturz method, respectively, and cutting trials are carried out on a five-axis machine tool. Experimental results show that the proposed method can avoid abrupt change of rotary axes of the machine tool and make the movement of machine axes more stable and smoother, and further obtain better machining quality and higher machining efficiency. Consequently, the proposed method will have important practical value.

Key words: ball-end cutter, kinematics constraints, multi-axis machining, sculptured surfaces, tool orientation

XU Rufeng, CHEN Zhitong, MENG Fanjun, ZHANG Yun, WU Xianzhen. Tool Orientation Optimization Method Based on Kinematics Constraints of the Machine Tool in Multi-axis Machining with a Ball-end Cutter[J]. Journal of Mechanical Engineering, 2015, 51(23): 160-167.

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