Tool path generation and optimization method for pocket flank milling of aircraft structural parts based on the constraints of cutting force and dynamic characteristics of machine tools

Abstract

The cutting force and vibration will be increased dramatically due to the sharp change of cutting engagement angle during the process of pocket flank milling for aircraft structural parts. And the sharp change of the curvature of tool path curves of pocket corner brings higher requirements for the performance of dynamic characteristics of the machine tool, while the machining quality of the surface will be affected heavily once the dynamic characteristics of the machine tool cannot meet the machining dynamic characteristics requirements. It is very important to consider the constraints of cutting force and dynamic characteristics of the machine tool during tool path generation. However, it is a contradictory problem to satisfy the requirement proposed by the two constraints on tool path, and it is not easy to compromise the two constraints. In order to address the difficult issue mentioned above, a new tool path generation and optimization method for pocket flank milling is proposed. The essential idea of this paper is the combination strategy of corner-looping milling and clothoid curve transition, where the contradictory requirement of the above two constraints can be compromised and optimized. The machining experiment results show that the conditions of cutting force can be improved, vibration during the process of machining can be reduce, as well as the machining quality of the surface is improved.