Proposal of a tool path generation method for rough machining of complex shapes based on topology optimization
Journal of Advanced Mechanical Design, Systems, and Manufacturing
Recently, the demand of complex shape parts has increased mainly in the aircraft and medical industries. In these parts machining, the displacement and vibration of workpiece that strongly affect the machining efficiency are induced as a result of the heavy change of the unmachined workpiece shape and stiffness while rough machining. On the other hand, it is difficult to automatically determine the manufacturing information by using a commercial CAM system because there is a large number of
... inations. Thus, in order to improve the machining efficiency of complex shape parts, the authors have proposed a determination method of workpiece transition shapes during a rough machining operation based on topology optimization. However, tool paths are not generated automatically to create the obtained workpiece transition shapes in the previous study. Therefore, in this study, a tool path generation method is proposed considering both static stiffness of workpiece and machining efficiency. The proposed method supposes 5-face milling and in the machining the tool orientation is determined to minimize the change of tool orientations by using the obtained parameters in topology optimization. The tool paths are continuously generated based on not only the design variables of topology optimization but also geometric feature of machining area, target shape, final support. A case study assuming rough machining of complex shape parts is conducted to confirm the effectiveness of the proposed method.