Tool path planning for five-axis U-pass milling of an impeller

Feng, Jingyang; Wei, Zhaocheng; Wang, Minjie; Wang, Xueqin; Guo, Minglong

doi:10.1007/s00170-021-07947-x

Cited by 5 publications

(4 citation statements)

References 30 publications

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“…It was determined that the system can increase processing accuracy and efficiency. Feng et al 22 conducted research on the finishing of aluminum alloy integral impeller root fillet. The novel approach uses cognitive processing to online monitor the burr shape of the blade root and adjust the cutter axis vectors and cutting settings to prevent over-cutting of the five-axis CNC machine tool during processing.…”

Section: Introductionmentioning

confidence: 99%

Multi-axis CNC finishing and surface roughness prediction of TC11 titanium alloy open integral micro impeller

Zhao,

Cao,

Guo

et al. 2024

Advances in Mechanical Engineering

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The titanium alloy open integral micro impeller has a strong material strength and high removal rate in the field of multi-axis CNC machining. The flow channel is tiny and the blades are thin and highly twisted. It is difficult to control the surface accuracy and prone to overcutting and undercutting. The NX2212 software post-processing module plans two distinct blade finishing process routes and verifies them using virtual machine tool simulation, taking into account the technical challenges of micro impeller machining. Following verification, the tool path machining code is imported into MATLAB for data fitting. The workpiece surface working condition is determined based on the simulation findings, the blade surface roughness value is calculated, and a physical simulation model of blade finishing is created in the finite element analysis software. The outcomes demonstrate how well the “segmented and sub-regional cutting” processing method may raise blade accuracy. The leading and trailing edges of the blade both had surface roughness increases of 4.86% and 4.19%. The surface morphology of the micro impeller is measured using a white light interferometer, and it is CNC machined using two distinct process methods. The findings demonstrate that there is a significant difference between the value calculated by the finite element analysis software and the surface roughness value measured experimentally which together make up less than 5%. An investigation of the impact of cutting parameters on the surface roughness of micro-structure components is carried out using a three factor, three-level BBD experiment that is founded on the second-order response surface method. The findings indicate that the feed per tooth influences surface roughness more significantly than cutting depth and cutting speed for a reasonable range of cutting parameters; Surface roughness will rise with lower or higher cutting speeds; Raising the feed per tooth and the cutting speed simultaneously may reduce surface roughness; Surface roughness can be accurately predicted and controlled using the second-order response surface method.

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Section: Introductionmentioning

confidence: 99%

Multi-axis CNC finishing and surface roughness prediction of TC11 titanium alloy open integral micro impeller

Zhao,

Cao,

Guo

et al. 2024

Advances in Mechanical Engineering

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“…The advantages of trochoidal milling in rough machining can be further enhanced by optimizing the toolpath, such as improving the toolpath continuity [15,16], shortening the toolpath length [2,14,17], balancing the engagement angle and the cutting load [32][33][34][35]. The true trochoidal toolpath has C 2 continuity and can avoid a sharp change in engagement angle and cutting force during the milling process, and this helps to improve the smoothness of machine tool movements [2,36].…”

Section: Introductionmentioning

confidence: 99%

Effects of Toolpath Parameters on Engagement Angle and Cutting Force in Ellipse-Based Trochoidal Milling of Titanium Alloy Ti-6Al-4V

Zhou

et al. 2023

Applied Sciences

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Trochoidal milling is an efficient strategy for the rough machining of difficult-to-cut materials. The true trochoidal toolpath has C2 continuity and avoids sharp changes in engagement angle and cutting load, resulting in smooth machine tool movement. However, its total length is too long, and its engagement angle is uneven. These factors limit further improvements in the material removal rate. Based on the true trochoidal toolpath model, this paper develops an ellipse-based trochoidal toolpath generation method by introducing a compression ratio in the trochoidal step direction. The analytical model of engagement angle and the mechanistic model of the cutting force are proposed. A series of simulations and milling experiments were conducted to analyze the effects of toolpath parameters on the engagement angle and the cutting force. The results show that the compression ratio has the most significant effects. A compression ratio of 50% is optimal, using which the total toolpath length is reduced by 34.0%, and the variance of the engagement angle is reduced by 31.2% compared with that of the true trochoidal toolpath. The profile of the total cutting force corresponds to that of the engagement angle.

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“…The virtual simulation system of the machining center confirmed that compared to the ball end milling cutter, the tool path trajectory was finer, the machining accuracy was higher, and it was easier to optimize the tool path. The machining accuracy error was 0.007-0.012 mm (Wei J. et al, 2021). Yu et al proposed a new calculation method for the error of the R-offset tool axis for the tool axis trajectory planning problem of NERS machining with conical cutting tools, and derived an accurate analysis using a formula.…”

mentioning

confidence: 99%

“…The three-axis milling groove test showed that the peak and average cutting forces decreased by 25% and 60%, respectively. Therefore, this method could reduce the instability of cutting force, improve machining efficiency, and reduce the degree of tool wear (Feng et al, 2021). Zhao et al proposed a structure that utilizes NiAl based high-temperature alloy for milling precision of narrow blade turbine impellers to achieve the milling accuracy of typical thin-walled structural components of turbine engines.…”

mentioning

confidence: 99%

Optimization of machining path for integral impeller side milling based on SA-PSO fusion algorithm in CNC machine tools

Zhao

2024

Front. Mech. Eng.

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The five axis linkage Computer Numerical Control machine tool for integral impeller can achieve blade machining through side milling, which is of great significance for improving the machining accuracy, production efficiency, and long-term stability of integral impeller blades. This study is based on non-uniform rational B-spline curves and aims to reduce the surface over cutting or under cutting of integral turbine blades. The path planning of non deployable ruled surfaces was analyzed in depth through side milling, and the path planning model of the side milling cutter axis was solved through a fusion algorithm of simulated annealing algorithm and particle swarm optimization algorithm, in order to find the optimal path through iterative process. As the number of iterations increased, the error values of particle swarm optimization algorithm and simulated annealing particle swarm optimization fusion algorithm gradually decreased, with convergence times of about 7 and 6, respectively. The stable error value of the fusion algorithm was 0.253, which is 30.45% lower than that of the particle swarm optimization algorithm. The optimal number of iterations for solving the model using particle swarm optimization algorithm and fusion algorithm was the 7th, with range values of 0.0213 and 0.0165 mm, respectively. The tool axis trajectory surface optimized by the fusion algorithm was closer to the tool axis motion state compared to the initial tool axis trajectory surface. The range of the sum of mean squared deviations for single and global cutting was 0.0011–0.0198 and 0.046–0.0341, but the overall error value was relatively small. This study effectively reduces the envelope error of machining tools and improves machining accuracy, thereby solving the principle error of non expandable ruled surfaces in the motion trajectory of the blade axis of the integral turbine. This provides new research ideas for the intelligent development of Computer Numerical Control machining technology.

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Tool path planning for five-axis U-pass milling of an impeller

Cited by 5 publications

References 30 publications

Multi-axis CNC finishing and surface roughness prediction of TC11 titanium alloy open integral micro impeller

Multi-axis CNC finishing and surface roughness prediction of TC11 titanium alloy open integral micro impeller

Effects of Toolpath Parameters on Engagement Angle and Cutting Force in Ellipse-Based Trochoidal Milling of Titanium Alloy Ti-6Al-4V

Optimization of machining path for integral impeller side milling based on SA-PSO fusion algorithm in CNC machine tools

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