Research And Application Of Tool Orientation Optimization For Five-axis Machining Based On Quasi-feasible Map

Five-axis machining is increasingly used in the machining of complex parts due to its high machining accuracy,wide range of machining possibilities and high machining efficiency.The selection of the optimum tool orientation plays an important role in workpiece quality,machining efficiency and machining costs.Therefore,it is particularly important to calculate the feasible map of the tool orientation.The existing method of traversing all orientations has a large number of tool orientations to be calculated and a large amount of computation.In order to solve this problem,this thesis puts forward the concept of tool orientation quasi-feasible map,which is an approximation of the feasible map of the tool orientation and can be used for tool optimization.Based on the tool orientation quasifeasible map,a tool optimization algorithm framework is proposed in this thesis.The calculation of the quasi-feasible map of the tool orientation mainly consists of two parts: the initialization of the quasi-feasible map of the tool orientation and the correction of the quasi-feasible map of the tool orientation.The initial solution of the tool orientation quasi-feasible map is mainly based on the similarity of the adjacent tool contact quasifeasible map and the boundary tracing method is adopted to obtain the tool orientation quasifeasible map of all the tool contacts in turn.The correction of the quasi-feasible map of the tool orientation is mainly aimed at the situation of complex obstacles,and the correction of the quasi-feasible map of the tool orientation and the optimization of the tool orientation are carried out in the way of iterative updating.Based on the tool orientation quasi-feasible map,a tool optimization strategy is proposed to reduce tool wear.In the quasi-feasible map of the tool orientation,the continuity of the tool orientation was taken as the constraint and the tool service life was improved as the goal.The tool orientation was optimized by using genetic algorithm to homogenize the tool wear.Finally,the simulation and machining experiments of the proposed algorithm are carried out by taking the slot workpiece and the impeller as examples.The simulation results show that the algorithm proposed in this thesis can effectively solve the interference problem.The simulation and machining results show that the tool optimization algorithm proposed in this thesis can effectively prolong the tool life compared with the machining method of fixed lead angle and tilt angle.