A cutting sequence optimization algorithm to reduce the workpiece deformation in thin-wall machining

• Published in: Precision engineering Vol. 50; pp. 506 - 514
• Main Authors: Wang, Jun, Ibaraki, Soichi, Matsubara, Atsushi
• Format: Journal Article
• Language: English
• Published: Elsevier Inc 01.10.2017
• Subjects: CAM (computer-aided manufacturing); Cutting process; Displacement; Thin wall; Tool path; Cutting process; Tool path; CAM (computer-aided manufacturing); Thin wall; Displacement
• DOI: 10.1016/j.precisioneng.2017.07.006
• ISSN: 0141-6359

•End milling of workpiece of lower stiffness is often subject to larger machining error.•Optimization of block removal reduces deformation in thin-wall milling.•No division of blocks in the feed direction avoids cutter marks and severe vibration.•Sub-division of blocks in the tool’s axial direction reduces deformation further. A thin-wall part of lower stiffness can be subject to significant deformation during its cutting process. This study proposes a cutting process optimization algorithm to reduce the workpiece deformation. First, the volume to be removed is divided into a set of blocks. The proposed algorithm starts from the finished workpiece shape, with all the blocks removed. The objective of the proposed algorithm is to find a sequence of adding the blocks, such that the workpiece deformation is always smaller than the given threshold value when the cutting forces is imposed at each step. The workpiece deformation at each step is simulated by using the FEM (finite element method) simulation. By inverting the sequence of adding the blocks, the optimized sequence to remove the blocks can be obtained. Additionally, the block size can be modified to reduce the axial depth of cut to further reduce the workpiece deformation, or to increase the radial depth of cut to enhance the efficiency. Experiments are conducted to confirm the effectiveness of the algorithm to reduce the maximum workpiece deformation during the entire cutting process.