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Improving the dynamics of five-axis machining through optimization of workpiece setup and tool orientations

机译：通过优化工件设置和刀具方向来改善五轴加工的动力学

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摘要

Existing works in optimization of five-axis machining mainly focus on the machining efficiency and precision, while the dynamic performance of the machine tools has not been fully addressed, especially in high-speed machining, in which the rotary actuators have limited dynamic ability. In this paper, a study is reported on how to generate a tool path so that the maximal angular accelerations of the rotary axes of the five-axis machine can be reduced. Two independent methods are proposed for this task: (1) by optimizing the setup of the workpiece on the machine's table, and (2) by finding better tilt and yaw angles for the tool orientations. In this paper, the setup parameters of the workpiece are incorporated into the inverse kinematic equations, and angular acceleration functions are established according to the numerical solutions of those equations. While varying the tool orientations unquestionably would affect the surface quality of the machining, we introduce the so called Domain of Geometric Constraints that will restrict the allowable tilt and yaw angle of the tool at the cutter contact points on the part surface, so to ensure the satisfaction of the requirement of both local-gouging-free and cusp-height. For the first method - finding the optimal workpiece setup - a heuristic-based approach, i.e., the Genetic Algorithm (GA), is adopted, whereas for the second method - the constrained optimization of tool orientations - we present an elaborate algorithm based on the results from the analysis conducted by the authors. At the end of the paper, computer simulation experiments are reported that demonstrate the effectiveness of our proposed methods and algorithms.
机译：现有的五轴加工优化中的工作主要集中在加工效率和精度上，而机床的动态性能尚未得到充分解决，特别是在旋转执行器的动态能力有限的高速加工中。在本文中，对如何生成刀具路径进行了研究，从而可以减小五轴机床旋转轴的最大角加速度。针对此任务，提出了两种独立的方法：（1）通过优化机床工作台上的工件设置，以及（2）通过针对刀具方向找到更好的倾斜角和偏航角。在本文中，将工件的设置参数纳入逆运动学方程，并根据这些方程的数值解建立角加速度函数。虽然改变刀具方向无疑会影响加工的表面质量，但我们引入了所谓的几何约束域，它将限制零件表面上刀具接触点处刀具的允许倾斜角和偏航角，因此要确保满足无局部气刨和尖顶高度的要求。对于第一种方法-找到最佳工件设置-采用基于启发式的方法，即遗传算法（GA），而对于第二种方法-刀具方向的约束优化-我们提出了一种基于由作者进行的分析得出的结果。在本文的最后，据报道计算机仿真实验证明了我们提出的方法和算法的有效性。

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