Abstract
In free-form surface machining, it is essential to optimize the feedrate in order to improve the machining efficiency. Conservative constant feedrate values have been mostly used up to now since there was a lack of physical models and optimization tools for the machining processes. The overall goal of this research is the integration of geometric and mechanistic milling models for force prediction and feedrate scheduling in five-axis CNC free-form surface machining. For each tool move, the geometric model calculates the cut geometry, and a mechanistic model is used along with a maximum allowable cutting force to determine a desired feedrate. The results are written into the part NC program with optimized feedrates. When the integrated modeling approach based feedrate scheduling strategy introduced in this paper was used, it was shown that the machining time can be decreased significantly along the tool path.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Lan TS, Hsu KS (2007) The implementation of optimum MRR on digital PC-based lathe system. Int J Adv Manufact Technol 35(3–4):248–254
Li ZZ, Zheng M, Liu DC (2003) A solid model-based milling process simulation and optimization system integrated with CAD/CAM. J Mate Process Technol 138(1–3):513–517
Yazar Z, Koch KF, Altan T (1994) Feedrate optimization based on cutting force calculations in 3-axis milling of dies and molds with sculptured surfaces. Int J Mach Tool Manufact 34(3):365–377
Lim M, Hsiang MC (1997) Integrated planning for precision machining of complex surface. Int J Mach Tool Manufact 37:77–91
Baek DK, Ko TJ, Kim HS (2006) Chip volume prediction using a numerical control verification model. Int J Mach Tool Manufact 46(12–13):1326–1335
Liu XW, Cheng K (2005) Improved dynamic cutting force model in ball-end milling. Part I: theoretical modeling and experimental calibration. Int J Adv Manufact Technol 26(5):465–475
Taunsi N, Elbestawi MA (2003) Optimized feed scheduling in three axes machining. Part I: Fundamentals of the optimized feed scheduling strategy. Int J Mach Tool Manufact 43:253–267
Feng HY, Su N (2000) Integrated tool path and feedrate optimization for finishing machining of 3D plane surfaces. Int J Mach Tool Manufact 40:1557–1572
Li ZZ, Zhang ZH, Zheng L (2004) Feedrate optimization for variant milling process based on cutting force prediction. Int J Adv Manufact Technol 24(7–8):541–552
Ko JH, Cho DW (2004) Feedrate scheduling model considering transverse rupture strength of a tool for 3D ball-end milling. Int J Mach Tool Manufact 44:1070–1076
Erdim H, Lazoglu I, Ozturk B (2006) Feedrate scheduling strategies for free-form surfaces. Int J Mach Tool Manufact 46(7–8):747–757
Guzel BU (2004) Increasing productivity in sculpture surface machining via off-line piecewise variable feedrate scheduling based on the force system model. Int J Mach Tool Manufact 44(1):21–28
Li JG, Zhao H, Yao YX, Liu CQ (2007) Off-line optimization on NC machining based on virtual machining. Int J Adv Manufact Technol (in press). DOI 10.1007/s00170-006-0915-6
Ko JH, Cho DW (2004) Feedrate scheduling model considering transverse rupture strength of a tool for 3D ball-end milling. Int J Mach Tool Manufact 44:1070–1076
Jang D, Kim K, Jung J (2000) Voxel-based virtual multi-axis machining. Int J Adv Manufact Technol 16(10):709–713
Huang YC, Oliver JH (1994) NC milling error assessment and tool path correction. Comput Graphics Proc 28(4):287–294
Fussell BK, Jerard RB, Hemmett JG (2003) Modeling of cutting geometry and forces for 5-axis sculptured surface machining. Computer-Aided Des 35(4):333–346
Jerard RB (2006) Process simulation and feedrate selection for three-axis sculptured surface machining. Int J Manufact Res 2:136–156
Fussel BK, Jerard RB, Hemmett JG (2001) Robust feedrate selection for 3-axis NC machining using discrete models. J Manufact Sci Engin 123:214–224
Lee HU, Cho DW (2003) An intelligent feedrate scheduling based on virtual machining. Int J Adv Manufact Technol 22(11–12):873–882
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Zhang, L., Feng, J., Wang, Y. et al. Feedrate scheduling strategy for free-form surface machining through an integrated geometric and mechanistic model. Int J Adv Manuf Technol 40, 1191–1201 (2009). https://doi.org/10.1007/s00170-008-1424-6
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-008-1424-6