Pareto multi-objective optimization of cutter orientation for 5-axis ball-end milling

被引:2
作者
Wang, Haitong [1 ,2 ]
Yang, Yuwei [1 ]
Mei, Jiawei [1 ,2 ]
Cai, Yonglin [1 ,2 ]
Lu, Minghui [1 ]
机构
[1] Beijing Jiaotong Univ, Digital Mfg Technol Lab, Beijing, Peoples R China
[2] Minist Educ, Key Lab Vehicle Adv Mfg Measuring & Control Techno, Beijing, Peoples R China
基金
中国国家自然科学基金;
关键词
Pareto multi-objective optimization; Chatter; Machining deformation; Cutter orientation; TOOL; STABILITY; DEFORMATION;
D O I
10.1007/s00170-025-15113-w
中图分类号
TP [自动化技术、计算机技术];
学科分类号
0812 ;
摘要
To improve the machining quality of free-form surfaces, machining deformation and chatter should be considered in 5-axis ball-end milling. In this paper, a Pareto multi-objective optimization method for cutter orientation is presented. Firstly, the cutting force is calculated by the differential element method. To improve the computational efficiency of cutting force, the proposed cutting force model considers the influence of surface curvature on the cutter workpiece engagement (CWE) region and gives an analytical calculation method. Then, the deformation and chatter of 5-axis ball-end milling are studied. The static deflection corresponding to different cutter orientations is calculated based on the large-scale sparse matrix inversion algorithm. The chatter-free stability region is calculated based on the 3-dimensional semi-discretization method (SDM). It was found experimentally that the smaller the eigenvalue of the SDM transition matrix is, the more stable the machining is and the better the surface quality is. On this basis, the minimum eigenvalue is proposed as optimization criteria for chatter. Finally, a non-dominated sorting genetic algorithm (NSGA-II) is used to obtain the Pareto optimal region of the cutter orientations. The optimization model takes the minimum value of static deflection and stability eigenvalue as optimization objectives. For each key cutter location point, the feasible region of the cutter orientations with high precision and surface quality is obtained based on NSGA-II. Furthermore, based on the optimization results at the key cutter location points, Dijkstra algorithm and quaternion interpolation algorithm were used to optimize the cutter orientations of the whole free-form surface, which ensured the kinematics performance of the 5-axis machine. The experimental results are in good agreement with the simulation results, which shows that the theoretical model is effective. The results provide a theoretical basis for the comprehensive optimization of machining deformation and chatter of thin-walled parts with the free-form surface.
引用
收藏
页码:4829 / 4846
页数:18
相关论文
共 50 条
[41]   Analysis of cutting forces and optimization of cutting parameters in high speed ball-end milling using response surface methodology and genetic algorithm [J].
Dikshit, Mithilesh Kumar ;
Puri, Asit Baran ;
Maity, Atanu ;
Banerjee, Amit Jyoti .
INTERNATIONAL CONFERENCE ON ADVANCES IN MANUFACTURING AND MATERIALS ENGINEERING (ICAMME 2014), 2014, 5 :1623-1632
[42]   Optimization of cutter orientation for multi-axis NC machining based on minimum energy consumption of motion axes [J].
Baohai Wu ;
Mancang Liang ;
Feiyan Han ;
Ying Zhang .
The International Journal of Advanced Manufacturing Technology, 2019, 104 :1855-1867
[43]   Optimization of cutter orientation for multi-axis NC machining based on minimum energy consumption of motion axes [J].
Wu, Baohai ;
Liang, Mancang ;
Han, Feiyan ;
Zhang, Ying .
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY, 2019, 104 (5-8) :1855-1867
[44]   Multi-objective Optimization of Ms58 Brass Machining Operation by Multi-axis CNC Lathe [J].
Secgin, Omer .
ARABIAN JOURNAL FOR SCIENCE AND ENGINEERING, 2021, 46 (03) :2133-2145
[45]   Research on the machined surface integrity under combination of various inclination angles in multi-axis ball end milling [J].
Chen, Xiaoxiao ;
Zhao, Jun ;
Dong, Yongwang ;
Li, Anhai ;
Wang, Dong .
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE, 2014, 228 (01) :31-50
[46]   Multi-objective optimization control for shield cutter wear and cutting performance using LightGBM and enhanced NSGA-II [J].
Yin, Ziwei ;
Jiao, Jianwei ;
Xie, Ping ;
Luo, Hanbin ;
Wei, Linchun .
AUTOMATION IN CONSTRUCTION, 2025, 171
[47]   Multi-objective optimization of composite airfoil fibre orientation under bending-torsion coupling for improved aerodynamic efficiency of horizontal axis wind turbine blade [J].
Mitra, Arka ;
Chakraborty, Arunasis .
JOURNAL OF WIND ENGINEERING AND INDUSTRIAL AERODYNAMICS, 2022, 221
[48]   Pareto multi-objective optimization of metro train energy-saving operation using improved NSGA-II algorithms [J].
Zhang, Zhenyu ;
Cheng, Xiaoqing ;
Xing, Zongyi ;
Gui, Xingdong .
CHAOS SOLITONS & FRACTALS, 2023, 176
[49]   Optimization and Prediction of Specific Energy Consumption in Ball-End Milling of Ti-6Al-4V Alloy Under MQL and Cryogenic Cooling/Lubrication Conditions [J].
Tesic, Sasa ;
Cica, Djordje ;
Borojevic, Stevo ;
Sredanovic, Branislav ;
Zeljkovic, Milan ;
Kramar, Davorin ;
Pusavec, Franci .
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING-GREEN TECHNOLOGY, 2022, 9 (06) :1427-1437
[50]   Highly efficient fabrication of reentrant microchannels with micro serrated pin fins using a micro staggered multi-edge ball-end milling tool in a single process [J].
Zhang, Zhenkun ;
Deng, Daxiang ;
Gu, Xin ;
Zeng, Long ;
Yao, Yingxue .
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY, 2025, 335