Research On Tool Path Generation Of Five-axis Milling Of Complex Channel Parts

The "Manufacturing 2025" promotes the development of intelligent equipment,automated processing,and digital manufacturing.High-efficiency machining of complex channel components has always been the focus of smart manufacturing research.The use of digital modeling,simulation,optimization to guide processing is of great significance for improving the quality of complex channel surfaces.The prototype design of the model is an indispensable part of production and directly affects the surface quality of the final machined parts.In addition,all the parameters in the machining process are mostly derived from the differential geometry of the original model surface.In this paper,the demands for complex channel components are firstly solved,and the surface reconstruction is achieved based on similar models.During the reconstruction process,the key feature extraction method is designed according to the characteristics of the model,which ensures the feature integrity in the resampling process.Using the curve discretization and re-fitting method to get the second-order continuous curve for the surface discontinuity of the original model.Then the final reconstructed surface is generated by means of skinning;verifies that the reconstructed model satisfies the design requirements through the surface quality analysis.Machining path planning is very important to surface accuracy and machining efficiency.This article comprehensively considers the factors such as the tool's position,residual height,machining trajectory,and step length in the tool's anisotropy.Based on the minimum curvature radius of the curve,the processing step is calculated,and the method of mapping the step distance to the parameter field of the surface to obtain the variable parameter machining tool path is proposed,and the problem of increasing the error due to the excessive processing step size is solved.The method of machining the tool path with variable parameter can ensure the consistency of the machining track boundary,and the machining trajectory can be adjusted as the curvature of the surface changes.In the process of discrete cutter location,in this paper,a four-step method is proposed.Based on the actual chord error,the tool path is divided into concave and convex sections,and then the step length is corrected by means of the mean curvature radius method.The results show that the approximation linear segment error obtained by this algorithm is smaller and the machining efficiency is faster.The range of the turret of the arbor is limited during the machining of the complex channellike surface parts,and the collision between the tool and the part is easy to occur.The change of the angle of the adjacent arbor generates the morphological change of the cutting area and affects the surface quality.The tool-shaft's pendulum range is limited,and collision between the tool and the part is likely to occur during machining of complex-path free-form surface parts.The change of the adjacent tool-axis angle results in the change of the shape of the cutting area and affects the surface quality.For the problem of the control of the tool axis of the complicated channel components,the rotating tool axis for collision test is used to determine the feasible region of the tool axis,problem of tool shaft sequence solving is converted into path search problem in three-dimensional space through C-Space mapping and overlay.Finally,the ant colony algorithm is used to search for the optimal path in three-dimensional space.This method avoids multiple corrections of the tool axis during the machining process.It can obtain the optimized tool axis of the entire tool path at a time and ensure the smoothness of the tool shaft sequence.