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Publication# High Speed Pocket Milling Optimisation

Résumé

The invention relates to a method of toolpath generation and cutting parameters optimization for high speed milling of a convex pocket, wherein said method comprises a first sub-method of generating a toolpath and a second sub-method of generating optimized chatfree cutting parameters using a genetic algorithm wherein the first sub-method generates milling toolpaths that minimize the radial depth of cut variations as well as the curvature change variations while avoiding leftover material at the corners, wherein said toolpaths automatically avoid self-intersecting features encountered during the offsetting of pocket boundary such that the said toolpaths result in reduction in milling time for a given maximum acceptable radial depth of cut and wherein said second sub-method allows the free choice of cutting parameters and optimizes the milling time and wherein the optimization method incorporates relevant milling constraints as milling stability constraint, cutting forces, machine-tool and cutting tool capabilities.

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Machine-outil

Une machine-outil est un équipement mécanique destiné à exécuter un usinage, ou autre tâche répétitive, avec une précision et une puissance adaptées. Elle imprime à un outil, qu'il soit fixe, mobile,

Fraisage

Le fraisage est un procédé de fabrication où l'enlèvement de matière sous forme de copeaux résulte de
la combinaison de deux mouvements : la rotation de l'outil de coupe, d'une part, et l'avancée de

Algorithme génétique

Les algorithmes génétiques appartiennent à la famille des algorithmes évolutionnistes. Leur but est d'obtenir une solution approchée à un problème d'optimisation, lorsqu'il n'existe pas de méthode exa

The milling process has been continuously optimized from many aspects: forces, velocities, stability, quality. Numerous papers have been published that report results in the domain of toolpath optimization with criteria such as raising the quality of the machined part, obtaining a stable machining process and maximizing the material removal rate. However, only recently researchers have started investigating the ecological impact of machining processes. With the constantly increasing prices of electrical energy and all environmental problems caused by the production and waste of the energy, it has become indispensable to look for ways to optimize machining processes from the energy consumption aspect, too. It is in this domain, then, that the work described in this dissertation contributes – to add a new criterion for the sustainable operation of machine tools: reducing the energy consumption during the use phase of the machine tool. The total energy spent in a machining process is the sum of power spent by all machine tool subsystems multiplied by the time that they are working. Therefore, the operating strategies for increasing energy efficiency for the high-speed machining processes must be oriented towards the reduction of the total machining time (productive and unproductive) and reduction of instantaneous consumed power in the machining process or, preferably, both. There are many causes for milling process time and energy inefficiency. The major sources of potential time reductions include: (i) the issues related to the geometry and topology of the toolpath („air-time”, overlapping segments, gouge and uncut regions, orientation of the toolpath), (ii) the issues related to the kinematics of the feed drives (the feed velocity/acceleration profile). The possible domains for power consumption reduction are related to the forces that exist in the machining process (cutting, inertial, gravitational and friction forces). The power invested to overcome the cutting force is necessary for the machining process but its consumption should be optimized through constant cutting engagement and feedrate scheduling strategies. The other forces are responsible for the pure mechanical power loss and they should be minimized. The optimization variables for inertial and gravitational forces include the feed motion profile and moving mass configuration, while friction losses are load and/or velocity dependent. In addition, there are some power losses in the electric components of machine tool drives (electrical power losses), whose dependency on velocity and mechanical load can also be modeled. Despite many research efforts to analyze and model the phenomena causing inefficiency of the machining process, they are usually not taken into account during milling process planning. In fact, rare are the attempts to use this knowledge to optimize the milling process with more than one of the above mentioned criteria. The reason for that lies in the fact that increasing the instantaneous values of tool engagement and feedrate in order to minimize total machining time also increases the consumed power and, indirectly, deteriorates the tool and/or destabilizes the cutting process. The existence of conflicting criteria in the objective functions imposes the use of evolutionary algorithms for multiobjective optimization. The process of experimental validation of such an optimization model requires costly and complex external hardware setup and it is also time consuming. Hence, there is an emerging need for the development of an accurate model, which would be used for the simulation of the milling process and testing the competing optimization strategies. The ultimate goal of contemporary manufacturing science and engineering is the development of a holistic virtual machine tool system. The motivation of this PhD research is to contribute to this objective by developing the “virtual milling process for prismatic parts (produced by 2.5D milling)”. This category of objects is selected, because the majority of CNC milling tasks can be performed using 2.5D milling. A very large number of mechanical parts are prismatic (their geometry consists exclusively of features that represent 2D contours extruded in a perpendicular direction). Parts that are even more complex are usually produced from a blank by a 2.5D roughing and 3D–5D finishing. Therefore, development of an accurate model of a 2.5D milling process represents a significant contribution to manufacturing engineering. Starting with above given problem description, we have defined the following research objectives: 1. Model power and energy consumption of a 2.5D milling machine as a function of the toolpath geometry (curvature and continuity), cutting engagement, real feedrate profiles and spindle rotational speed, taking into account moving mass configuration, all power losses (mechanical and electrical) in feed-axis and spindle drives and electromechanical constraints of servo drives; 2. Design an integrated software environment for simulation of the developed models; 3. Validate the model experimentally; 4. Demonstrate the potential of its use for multi-objective process optimization. Cutting engagement calculation is performed by using two competing methodologies, in order to make a comparison of their performances. The first one, the pixel based method, is based on discrete image processing, while the other, the exact method, is based on Boolean operations and vector geometry. The tests performed in more than 20 feature/toolpath combinations demonstrate that the exact method is more precise whereas the pixel-based method is computationally much faster. The machine tool operator commands a constant feedrate value. During the process, based on his/her subjective judgment, he/she can manually tune it to keep the process in the desired boundaries. One of the objectives of this research is to predict the real feedrate values so that they can be integrated in the part program before the process start. The feasible profiles of feed velocities for each toolpath segment are analyzed by answering the following questions: can the commanded feedrate be achieved and with what sequence of acceleration and deceleration phases, how much the tool has to slow down in corners and how does the feedrate profile degenerate in segments where the commanded feedrate cannot be reached? In order to determine all forces and torques, a machine tool model is developed. The following subsystems are modeled as rigid bodies (without vibrations): feed motor shaft, transmission, lead screw/nut pair, lead screw bearings, guides (sliding and rolling design), table with the workpiece and electrospindle (rotor, stator and bearings). All kinetic variables (linear and angular speeds; cutting, inertial and friction forces and torques) are then calculated in the joints of this multi-body system. The modeling of all speeds, forces and torques that occur in the machine tool system during the machining process, allows for calculation of various indicators of process time and energy efficiency: material removal rate, total machining time, useful power (invested in cutting), power loss due to the friction in the joints, power losses in electrical motors, electrical energy consumption of feed and spindle drives. In order to assess the accuracy and the reliability of the developed model two sets of experiments have been performed. The model validation is performed on several subsystem levels and the simulation results show a very good compliance with the experimental results. The first experimental setup consists of the force dynamometer, to measure cutting force components in linear axis directions, two laser optical position sensors, to measure the real feedrate and the power sensor, to measure the total power consumption of the machine tool electrical motors. The machining process was performed on the 6-axis machining center C.B. Ferrari A152 and the data acquisition platform was developed in LabVIEW 2010. The second experimental setup consists of the torque dynamometer, to measure the cutting torque directly on the spindle, the built-in current sensor that measures the motor current proportional to the electrical power consumed by the spindle and, again, the power sensor, to measure the total power consumption of the machine tool electrical motors. This time, MIKRON HPM 600U, a 5-axis milling machine equipped with the controller iTNC530, was used for the experimentation. The developed model is ready for practical implementation. Several examples have been prepared to demonstrate its capabilities in the domains of milling process simulation, sensitivity analysis and prospective optimization strategies. These examples include the prediction of various kinetostatic variables for given toolpaths, choice of the optimum machining strategy (minimization of machining time, moving mass and energy consumption) and process optimization by feedrate scheduling (reduction of cutting force fluctuation). As a conclusion, the major contribution of this PhD research is the development of a comprehensive rigid-body dynamics model of a machine tool system, aimed for the generation, simulation and optimization of 21⁄2D milling process plans. The model features several novelties compared to existing approaches: (i) it takes into account the machine tool rigid body dynamics and real tool kinematics in toolpath planning, (ii) it predicts all mechanical and electrical power losses in the machine tool system (iii) it allows the modeling of machine tool system electromechanical constraints. The model was experimentally validated on two real machine tools in different workshops and its capabilities for the simulation of different toolpath patterns and optimization of process parameters were successfully demonstrated using several examples.

François Avellan, Christophe Tournier, Christian Vessaz

In a conventional design and manufacturing process, turbine blades are modeled based on reverse engineering or on parametric modeling with Computer Fluids Dynamics (CFD) optimization. Then, only raises the question of the manufacturing of the blades. As the design does not take into account machining constraints and especially tool path computation issues in flank milling, the actual performance of the machined blade could not be optimal. In this paper, a new approach is used for the design and manufacture of turbine blades in order to ensure that the simulated machined surface produces the expected hydraulic properties. This consists in the modeling of a continuous tool path based on numerical simulation rather than the blade surface itself. Consequently, this paper aims at defining the steps of the proposed design approach including geometrical modeling, mesh generation, CFD simulation and genetic optimization. The method is applied on an isolated blade profile in a uniform water flow and results are compared to the conventional design process.

2013The rigid body motion of thin walled parts and their elastic-plastic deformations induced during high speed milling are the main root causes of part geometrical and dimensional variabilities; these are governed mainly from the choice of process plan parameters such as; fixture layout design, operation sequence, tool path strategies and the values of cutting variables. Therefore, to avoid failures and achieve better machining results it becomes necessary to judge the validity of a given process plan before going into actual machining. After carefully reviewing previous research works for machined part quality analysis of milled parts, it is apparent that the task of milling process verification and optimization considering the effects of overall machining process parameters viz. fixture layout, operation sequence, tool path and cutting parameters on part quality, is complex, needing the development of a generalized methodology based on scientific principles. It is the purpose of the proposed work to address the problem and develop a sound methodology for the prediction and reduction of errors(resulting from rigid-elastic displacements) induced during machining of thin wall prismatic parts(those needing 2.5 axis machining). In this dissertation, a state of the art milling process plan verification and optimization system called FEM-Mill has been developed. The main novelties of the developed system lies in its two important computational modules namely; (i) the FEM based 3D transient milling simulation environment to predict part errors, and (ii)The rule based expert system for diagnosis and rectification of part error causes(if any). The system also incorporates a newly developed GA (genetic algorithm) model to maximize milling productivity through optimal selection of cutting parameters respecting the machine-tool technological constrains such as, spindle power, cutter safety, cutting parameter limits etc. The aforesaid computation modules along with a feature based process planner and a generalized machining load model(ANN(Artificial Neural Network) based) are successfully developed and implemented using APDL (ANSYS parametric design language) and C++ programming language. The proposed system was extensively tested for a variety of prismatic parts with different degrees of geometrical complexities and various combinations of cutting parameters and fixture assemblies taken from the industrial partners viz., (i) MCM s.p.a, Italy, a medium size machining center manufacturing enterprise and (ii) Quinson s.a., France, aircraft part manufacturer. The obtained transient numerical results namely, the cutting force, workpiece temperature distribution, part deflection and stresses for different part geometries were validated with real field data experimentally obtained during the course of this research work. A good agreement between the numerical and experimental data show the validity of the presented FEM based milling simulation model in handling real field problems. The developed milling simulation model would be an efficient means for analyzing the thermal-structural aspects of machining and their influence on the resulting machined part quality. Thus it allows manufacturing engineers in setting appropriate machining process parameters and obtaining better machining results without needing preliminary cutting trials which generally demand huge investment both in terms of Time and Money. This dissertation deals with a review of relevant literature, design of the modular architecture of FEM-Mill and detailed description of the developed computational methodologies along with demonstrations of the functional capabilities of the system with the help of some industrial test cases.