Research Of Intelligent Machining Of Complex Cavities Based On Optimal-radius Trochoidal Toolpath

As the development of NC post-process and HSM(high-speed milling) machine, it is the research hotspot that how to generate the HSM tool path of cavities. For the weakness in MRR(Material remove rate) and smoothness, there is always severe vibration and cutting-force mutation in traditional milling tool path of high speed milling. Especially in recent years, the proposal of trochoidal tool path is used to deal with the difficult part in the high speed roughing, which has been gotten more and more attention. But the strategy of trochoidal tool path has not been researched, it is hard to get high processing efficiency even by rich experience. So it’s the key problem in HSM that design the high-efficiency trochoidal tool path intelligently in the complex cavity. In this paper, the tool path planning of HSM roughing is studied, the aim is to make strategy that can intelligently generate the milling tool path for cavity with complex islands inside. Its main contents contain:Mathematical model of optimal-radius trochoidal tool path based on RDC(radial depth of cut) theory is proposed. For complex areas of the cavities, this model can generate milling tool path with relatively stable CSA(cutter swept angle), which can effectively control mutations of the cutting force. Compared to the previous constant-radius trochoidal model, this model can adaptively adjust the trochoidal radius according to the region shape, reducing the tool path redundancy effectively. In addition, compared with the previous C1 continuous model, this model can generate the toolpath whose tangent and the feed rate are C2 continuous, which is more suitable for high speed milling. The application of RDC(radial depth of cut) theory provides the theory and algorithm basis for setting parameters of optimal-radius trochoidal tool path.HSM tool path planning strategy based on CSA theory and Optimal-radius trochoidal tool path model is proposed. For complex cavity with multi-islands, the strategy could recognize the critical regions using trochoidal milling, whose aiming is keep the cutting force stable and improve cutting efficiency by reducing redundancy. The strategy recognize the critical region based on CSA. And the quantization of the critical region is according tool and region characteristic. At last, the optimal-radius trochoidal tool path is generated by using Voronoi. So the tool path generation method mixing using trochoidal and contour-parallel strategy.Applicant and verify the theory by the comparison between the new tool path strategy and the previous strategy using two standard which is cutting force and efficiency on the new experimental platform. Verify the optimal-various trochoidal tool path by comparing with previous ones. Verify the high efficiency of new milling strategy by comparing with the previous ones designed by UG.