Tool Orientation Optimization for Disk Milling Process Based on Torque Balance Method

Abstract

Disk milling strategy has been applied in grooving for decades for its capacity to provide huge milling force on difficult-to-cut material. However, basic research on the tool orientation of the disk milling cutter for the disk milling process on the milling free surface, especially on the free surface of the blisk, is still lacking in previous studies. In this study, the minimum residual amount after the disc milling process is used as an optimization target to obtain the optimal tool orientation of the disc cutter. To address the problem mentioned above, a torque balance method, including a torque balance algorithm and concentric circle ray point (CCRP) method is proposed. The torque calculation and torque balance problem are solved by the torque balance algorithm and the problem of generating random points to cause torque symmetry is solved in the CCRP method. Based on the secondary development of UG NX software, a series of tool orientation of disk milling cutter are calculated. Finally, the torque balance method is compared with steepest descent method, Newton method, and conjugate gradient method in the aspects of calculation accuracy, operation speed, and convergence speed. However, both the calculation speed and the convergence speed are better than the other three algorithms. Compared with the other three methods, the operation speed of the torque balance method is reduced by 0.35 times, 1.5 times, and 2.25 times. The results prove the feasibility of the torque balance method in solving the problem of tool orientation optimization of the disk milling cutter.