Process Planning Optimization For Five-Axis Sculptured Surfaces Finishing

Abstract

This thesis presents the research on the process planning optimization problem for 5-axis finish-cut milling of sculptured surfaces with the objectives of interference-free and maximizing machining efficiency. The proposed optimization approaches are based on the accessibility map construction algorithm developed in our previous study. The main issues addressed include multi-cutter selection and tool-path generation. Firstly, an innovative approach on multi-cutter set selection for 5-axis finish cut has been presented. Secondly, an optimization approach on iso-planar CL path generation for a cutter/cutting-region combination has been presented. The algorithm on optimal cutting direction selection has been developed aiming at maximum cutting efficiency. The overall process planning system has been implemented in a Visual C++ environment. Tests have been conducted on various types of sculptured surfaces and the efficacy and effectiveness of the proposed methods have been proved.