Abstract
This article presents an approach to generate optimal couples of tool size and tool path for flank milling ruled surface with a conical cutter based on normal mapping, while at the same time keeping this couples within the given bounded constraints. For given initial pairs of taper tool and tool path, tool envelope surface is calculated. Then, the tool axis trajectory surface is related to envelope surface through the normal mapping. On this basis, the correspondence between the surface pair “design ruled surface–envelope surface–tool axis trajectory surface” is established, and it is used to obtain the signed flank milling error. By using this signed error, tool size and tool path optimization for flank milling is formulated as an optimization model subjected to bounds, and the trust-region-reflective least-squares method is used to solve this problem. Numerical example is given to confirm the validity of the proposed method.
Highlights
Flank milling is an operation to machine the workpiece with the side part of a cutter
The flank milling error is reduced from the perspective of tool path optimization, including local optimization and global optimization
By virtue of normal mapping and associated signed flank milling error, we presented an alternative way to deal with this problem
Summary
Flank milling is an operation to machine the workpiece with the side part of a cutter. This milling method is highly recommended for machining blades with ruled surface, because it allows access to areas that would be inaccessible to end milling. When the non-developable ruled surface is flank-milled with cylindrical or conical tool, interference between the tool and the machined surface inevitably exists.[1,2] This is the starting point of research on flank milling, and more methods are proposed to reduce this error.[3]. Bedi et al.[5] located the cutter by making it tangent to the two directrices at both ends of the rule surface. Chiou[9] suggested adjusting the initial cutter location to reduce flank milling error by comparing the swept profile with the design surface.
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