Piecewise Decoupling Tool Orientation Re-Scheduling for Four-Axis Reciprocal Toolpaths of Blades Based on <i>S</i>-<i>θ</i> Plane with Monotonicity Constraint
Reciprocal toolpaths with four-axis simultaneous motion of five-axis or four-axis machine tools are commonly used in the machining of blades which are widely applied in high-end equipment such as the aero-engine and the marine steam turbine. Due to the complex geometry of the blades, the tool orient...
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| Format: | Article |
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MDPI AG
2022-10-01
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| Series: | Machines |
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| Online Access: | https://www.mdpi.com/2075-1702/10/10/953 |
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| author | Jingsong Li Dening Song Peiyao Li Qiang Zhang Jinghua Li Jianwei Ma |
| author_facet | Jingsong Li Dening Song Peiyao Li Qiang Zhang Jinghua Li Jianwei Ma |
| author_sort | Jingsong Li |
| collection | DOAJ |
| description | Reciprocal toolpaths with four-axis simultaneous motion of five-axis or four-axis machine tools are commonly used in the machining of blades which are widely applied in high-end equipment such as the aero-engine and the marine steam turbine. Due to the complex geometry of the blades, the tool orientation always suffers from frequent swing for this kind of toolpaths, which induces unnecessary acceleration/deceleration of the feed axes, thus degrading processing efficiency and quality. Although there are tool orientation optimization methods aiming at solving the above problem, they are mainly proposed for universal processing of the toolpaths for complex surfaces. Different from them, this paper proposes a piecewise decoupling tool orientation re-scheduling method for this kind of toolpath specifically, which takes full use of the characteristic of the reciprocal toolpaths of the blades, and takes the monotonous variation of rotation axes as an additional constraint. The re-scheduling process is realized based on the construction of a <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mi>S</mi></semantics></math></inline-formula>-<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mo>θ</mo></semantics></math></inline-formula> plane, where the scheduling problem is converted to the adjustment of a <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mi>S</mi></semantics></math></inline-formula>-<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mo>θ</mo></semantics></math></inline-formula> curve inside a feasible channel. Through two procedures, namely linearization scheduling and control-point assigning-based smoothing, the tool orientation path expressed by the <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mi>S</mi></semantics></math></inline-formula>-<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mo>θ</mo></semantics></math></inline-formula> curve can be effectively scheduled in a piecewise manner, and the smoothness between two adjacent pieces of the toolpaths can be ensured directly. The whole algorithm is lightweight and does not involve complex iterative operations or functional optimization solutions. Simulation and experimental tests verify the feasibility and superiority of this method. The results show that the machining efficiency of the blade is improved by 24.5%, due to the reduction of the requirement on highest feed-axis kinematics parameters after rescheduling. In addition, compared with the existing methods, the proposed method not only can improve the dynamics of feed axes in multi-axis machining, but also has advantages in computational complexity and monotonic variation property of the tool orientation. |
| first_indexed | 2024-03-09T19:55:21Z |
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| institution | Directory Open Access Journal |
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| last_indexed | 2024-03-09T19:55:21Z |
| publishDate | 2022-10-01 |
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| series | Machines |
| spelling | doaj.art-b31e19863f4a4a9ba05b81b41edb42ac2023-11-24T01:00:09ZengMDPI AGMachines2075-17022022-10-01101095310.3390/machines10100953Piecewise Decoupling Tool Orientation Re-Scheduling for Four-Axis Reciprocal Toolpaths of Blades Based on <i>S</i>-<i>θ</i> Plane with Monotonicity ConstraintJingsong Li0Dening Song1Peiyao Li2Qiang Zhang3Jinghua Li4Jianwei Ma5College of Mechanical and Electrical Engineering, Harbin Engineering University, Harbin 150001, ChinaCollege of Mechanical and Electrical Engineering, Harbin Engineering University, Harbin 150001, ChinaCollege of Mechanical and Electrical Engineering, Harbin Engineering University, Harbin 150001, ChinaHarbin Turbine Company Limited, Harbin 150001, ChinaCollege of Mechanical and Electrical Engineering, Harbin Engineering University, Harbin 150001, ChinaKey Laboratory for Precision and Non-Traditional Machining Technology of the Ministry of Education, School of Mechanical Engineering, Dalian University of Technology, Dalian 116024, ChinaReciprocal toolpaths with four-axis simultaneous motion of five-axis or four-axis machine tools are commonly used in the machining of blades which are widely applied in high-end equipment such as the aero-engine and the marine steam turbine. Due to the complex geometry of the blades, the tool orientation always suffers from frequent swing for this kind of toolpaths, which induces unnecessary acceleration/deceleration of the feed axes, thus degrading processing efficiency and quality. Although there are tool orientation optimization methods aiming at solving the above problem, they are mainly proposed for universal processing of the toolpaths for complex surfaces. Different from them, this paper proposes a piecewise decoupling tool orientation re-scheduling method for this kind of toolpath specifically, which takes full use of the characteristic of the reciprocal toolpaths of the blades, and takes the monotonous variation of rotation axes as an additional constraint. The re-scheduling process is realized based on the construction of a <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mi>S</mi></semantics></math></inline-formula>-<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mo>θ</mo></semantics></math></inline-formula> plane, where the scheduling problem is converted to the adjustment of a <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mi>S</mi></semantics></math></inline-formula>-<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mo>θ</mo></semantics></math></inline-formula> curve inside a feasible channel. Through two procedures, namely linearization scheduling and control-point assigning-based smoothing, the tool orientation path expressed by the <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mi>S</mi></semantics></math></inline-formula>-<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mo>θ</mo></semantics></math></inline-formula> curve can be effectively scheduled in a piecewise manner, and the smoothness between two adjacent pieces of the toolpaths can be ensured directly. The whole algorithm is lightweight and does not involve complex iterative operations or functional optimization solutions. Simulation and experimental tests verify the feasibility and superiority of this method. The results show that the machining efficiency of the blade is improved by 24.5%, due to the reduction of the requirement on highest feed-axis kinematics parameters after rescheduling. In addition, compared with the existing methods, the proposed method not only can improve the dynamics of feed axes in multi-axis machining, but also has advantages in computational complexity and monotonic variation property of the tool orientation.https://www.mdpi.com/2075-1702/10/10/953tool orientationtoolpath optimizationreciprocal toolpathsdecoupling schedulingmulti-axis machining |
| spellingShingle | Jingsong Li Dening Song Peiyao Li Qiang Zhang Jinghua Li Jianwei Ma Piecewise Decoupling Tool Orientation Re-Scheduling for Four-Axis Reciprocal Toolpaths of Blades Based on <i>S</i>-<i>θ</i> Plane with Monotonicity Constraint Machines tool orientation toolpath optimization reciprocal toolpaths decoupling scheduling multi-axis machining |
| title | Piecewise Decoupling Tool Orientation Re-Scheduling for Four-Axis Reciprocal Toolpaths of Blades Based on <i>S</i>-<i>θ</i> Plane with Monotonicity Constraint |
| title_full | Piecewise Decoupling Tool Orientation Re-Scheduling for Four-Axis Reciprocal Toolpaths of Blades Based on <i>S</i>-<i>θ</i> Plane with Monotonicity Constraint |
| title_fullStr | Piecewise Decoupling Tool Orientation Re-Scheduling for Four-Axis Reciprocal Toolpaths of Blades Based on <i>S</i>-<i>θ</i> Plane with Monotonicity Constraint |
| title_full_unstemmed | Piecewise Decoupling Tool Orientation Re-Scheduling for Four-Axis Reciprocal Toolpaths of Blades Based on <i>S</i>-<i>θ</i> Plane with Monotonicity Constraint |
| title_short | Piecewise Decoupling Tool Orientation Re-Scheduling for Four-Axis Reciprocal Toolpaths of Blades Based on <i>S</i>-<i>θ</i> Plane with Monotonicity Constraint |
| title_sort | piecewise decoupling tool orientation re scheduling for four axis reciprocal toolpaths of blades based on i s i i θ i plane with monotonicity constraint |
| topic | tool orientation toolpath optimization reciprocal toolpaths decoupling scheduling multi-axis machining |
| url | https://www.mdpi.com/2075-1702/10/10/953 |
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