Integrated tool path and feed rate optimization for the finishing machining of 3D plane surfaces

Abstract

An integrated approach for the concurrent optimization of tool path and feed rate for the finishing machining of 3D plane surfaces using ball-end milling is presented in this paper. This work is important, as the developed optimization approach is readily applicable to the finishing machining of sculptured surfaces. The concurrently optimized tool path and feed rate correspond to the maximum machining efficiency and satisfy the scallop height and machining error requirements. The cutter feed direction is employed as the optimization variable. For each cutter feed direction, tool path is determined according to the scallop height requirement and feed rate is maximized with the tolerance requirement by using a mechanistic cutting force model for three-dimensional ball-end milling. Optimization results have indicated that the shortest total tool path length, favored by most existing optimization approaches, does not result in maximum efficiency because the corresponding feed rate is often constrained by the specified tolerance. The optimum cutter feed direction is in general not unique but falls within an optimum range in the finishing machining of 3D plane surfaces.