An effective and automatic approach for parameters optimization of complex end milling process based on virtual machining

The demand for optimization of manufacturing processes rises as a reflection of the highly competitive market environment that requires shorter lead time and lower production costs. Although some approaches to milling process optimization have been developed based on analytical model using average cutting parameters, they are not available for complex workpieces when cutting parameters are time-varying and instantaneous cutting conditions need to be considered. In order to automate the optimization process and avoid costly machining tests, in this paper, an effective approach for parameters optimization of complex end milling process based on virtual machining is proposed. A computer-aided design (CAD)/computer-aided manufacturing (CAM) application is integrated for actual tool path generation and feedrate scheduling based on material removal rate. Then, a machining simulator based on octree and instantaneous force model is developed to evaluate feasibility of the given numerical control (NC) program, and the correctness of this simulator is verified by machining tests. The optimization process is controlled by the efficient global optimization method to find global optimal solution with fewer simulations and less computation time. During each iteration of the optimization process, NC programs are generated and evaluated automatically by the CAD/CAM application and the simulator, respectively. The effectiveness and efficiency of the proposed approach are proved by comparing the generated optimal solution (has reduced machining time and production cost) with the recommended cutting parameters from machining experts when machining an impeller.