Feedrate optimization method based on machining allowance optimization and constant power constraint

Aiming at the problem of low machining efficiency caused by the constant feedrate set by craftsmen in CNC machining, a feedrate optimization method by effectively combining the allowance optimization and the constant power constraint is developed in this paper. Firstly, the paper presents a machining allowance optimization method and corresponding hierarchical solution strategy to calculate machining allowance distribution. Then, a milling power prediction model is established on the basis of the milling force model and its accuracy is verified by the power model verification experiments. Furthermore, a feedrate optimization method with the spindle constant power constraint and a principle of secondary fine optimization are proposed. Finally, the allowance optimization of the complex part is carried out to obtain the positioning parameters and the optimal machining allowance distribution of the blank. Based on the machining allowance optimization results, the effectiveness of the feedrate optimization method is verified by the complex part machining optimization experiments. The experimental results show that the real-time power is maintained within the range of [−5.88%, 7.31%] of given target power value, reaching constant power constraint. It significantly shortens the processing time, improves the efficiency by 26.88%, and reduces the cost under the premise of protecting the machine tool and cutter. In this paper, the integrated optimization process from the determination of the blank quality to the processing parameter optimization is systematically completed.