Milling plan optimization with an emergent problem solving approach

An analytical model taking feed rate effect into consideration for scallop height calculation in milling with torus-end cutter

“…As a short term perspective the authors plan to apply this new method for calculation of the effective scallop height to recent toolpath planning algorithms such as zone machining algorithms described in Perles et al (2015) and Djebali et al (2015). Indeed, in the context of toolpath planning process the present work may be very useful to define the most efficient feedrate.…”

“…Studies on the first lever, that is to limit the length of the tool path, are numerous, the trajectories are calculated so that the scallop height between two consecutive paths is higher as possible without exceeding the imposed maximum height- Djebali et al (2015), Perles et al (2015) and Redonnet et al (2016). The problem is generally to space the more the paths to minimize tool-path length and thereby the machining time.…”

Blackbox optimization and surrogate models for machining free-form surfaces

“…The idea is to use a clustering approach to partition the surface based on a metric specifically dedicated to free-form surface clustering. Other works on surface partitioning include heuristic-based methods inspired by the Vehicle Routing Problem [7], an approach based on Adaptive Multi-Agent Systems [8], and an approach based on the concept of efficiency intervals (set of directions where toroidal cutter is better than ball-end one) is proposed by [9]. In [10], surface zones are generated based on a vector field of locally-optimal machining directions.…”

A new method for choosing between ball-end cutter and toroidal cutter when machining free-form surfaces

“…It has been proven in [14] that the effective radius of a toroidal cutter of radii R and r is superior to that obtained by a spherical tool of radius R, when the angle α is within the range [−35 • , 35 • ]. This condition is sufficient regardless of the values of R, r and s.…”

“…Testing the proposed procedure on this surface is conducted as follows: The characteristic size of the plane spanned by eigenvectors is equal toχ = 3137 mm 2 ; note that this value is close to the area of the surface. Knowing thatμ = 1.19, the critical slope can be calculated using Equation (14) and is equal to s c (μ) = 62.6 • . Sinces < s c , our approach predicts that the toroidal cutter will present a shorter machining time, which agrees with the numerical results.…”