Virtual five-axis flank milling of jet engine impellers - Part II: Feed rate optimization of five-axis flank milling

This paper presents optimization schemes for the five-axis flank milling of jet engine impellers based on the mechanics model explained in Part I. The process is optimized by varying the feed automatically as the tool-workpiece engagements, i.e. the process, varies along the tool path. The feed is adjusted by limiting feed-dependent peak outputs to a set of user-defined constraints. These outputs are tool shank bending stress, tool deflection, maximum chip load (to avoid edge chipping) and the torque limit of the machine. The linear and angular feeds of the machine are optimized by two different methods -- a multi-constraint based virtual adaptive control of the process and a non-linear root finding algorithm. The five-axis milling process is simulated in a virtual environment, and the resulting process outputs are stored at each position along the tool path. The process is recursively fitted to a first order process with a time varying gain and a fixed time constant, and a simple Proportional Integral controller is adaptively tuned to operate the machine at threshold levels by manipulating the feedrate. As an alternative to virtual adaptive process control, the feedrate is optimized by a non-linear root-finding algorithm. The optimum feed is solved for iteratively, respecting tool stress, tool deflection, torque and chip load constraints, using a non-linear root finding algorithm. Both methods are shown to produce almost identical optimized feed rate profiles for the roughing tool path discussed in Part I of the paper. The new feed rate profiles are shown to considerably reduce the cycle time of the impeller while avoiding process faults that may damage the part or the machine.