Mechanical Engineering

Hybrid Toolpath Planning and Feed Rate Optimization for Cavity Machining Under Constant Loads

  • WANG Qinghui ,
  • WANG Jinqiang ,
  • DING Xuesong ,
  • LIAO Zhaoyang
Expand
  • 1.School of Mechanical and Automotive Engineering,South China University of Technology,Guangzhou 510640,Guangdong,China
    2.Guangdong Key Laboratory of Modern Control Technology,Institute of Intelligent Manufacturing of Guangdong Academy of Sciences,Guangzhou 510070,Guangdong,China
王清辉(1972—),男,教授,博士生导师,主要从事CAD/CAM技术、VR交互研究。E-mail: wqh@scut.edu.cn

Received date: 2024-09-18

  Online published: 2024-12-13

Supported by

the National Key Research and Development Program of China(2022YFB4500600);Guangdong Basic and Applied Basic Research Foundation(2025A1515011849)

Abstract

The CNC machining of molds and various 3D parts involves numerous cavity features, and the design of machining toolpaths directly affects machining quality and efficiency. With the advancements in high-speed milling technology, CNC machines provide the hardware foundation for improving cavity machining efficiency, but they also place higher demands on CAM toolpath design. Traditional CAM toolpaths tend to cause abrupt changes in cutting load when dealing with areas such as cavity corners, slots, and intersections of circular paths. This load instability limits the improvement of feed rate and cutting depth, negatively impacting both machining efficiency and quality. To address these issues, this paper proposes a hybrid toolpath planning and feed rate optimization method aiming at achieving constant load machining for cavities. The method, which is based on a multi-level block structure, first calculates the material removal rate and then divides the machining areas into stable, semi-stable and load fluctuation regions. For different regions, circular toolpaths, feed speed optimization and variable-radius trochoidal paths are comprehensively adopted to ensure smooth load control throughout the machining process. By applying trochoidal paths in areas prone to load fluctuations, sudden load variations can be reduced and stable machining process can be ensured. Experimental results show that the proposed toolpath planning and feed rate optimization method is suitable for generating CAM toolpaths for various complex cavities, with good load stability and better machining quality.

Cite this article

WANG Qinghui , WANG Jinqiang , DING Xuesong , LIAO Zhaoyang . Hybrid Toolpath Planning and Feed Rate Optimization for Cavity Machining Under Constant Loads[J]. Journal of South China University of Technology(Natural Science), 2025 , 53(5) : 1 -10 . DOI: 10.12141/j.issn.1000-565X.240467

References

1 LEI S, LI M, XU S,et al .Reviews of mould corner milling[C]∥Proceedings of 2013 2nd International Conference on Measurement,Information and Control.Harbin:IEEE,2013:1412-1415.
2 CHOY H, CHAN K .Modelling cutter swept angle at cornering cut[J].International Journal of CAD/CAM20033(1):1-12.
3 IBARAKI S, YAMAJI I, MATSUBARA A .On the removal of critical cutting regions by trochoidal grooving[J].Precision Engineering201034(3):467-473.
4 HE G, MA W, YU G,et al .Modeling and experimental validation of cutting forces in five-axis ball-end milling based on true tooth trajectory[J].International Journal of Advanced Manufacturing Technology201578(1):189-197.
5 QI H, TIAN Y, ZHANG D .Machining forces prediction for peripheral milling of low-rigidity component with curved geometry[J].The International Journal of Advanced Manufacturing Technology201364(9):1599-1610.
6 H-S PARK, QI B, DANG D-V,et al .Development of smart machining system for optimizing feedrates to minimize machining time[J].Journal of Computational Design & Engineering20185(3):299-304.
7 KIM H-C, LEE S-G, YANG M-Y .An optimized contour parallel tool path for 2D milling with flat endmill[J].International Journal of Advanced Manufacturing Technology200631(5):567-573.
8 ERDIM H, LAZOGLU I, OZTURK B .Feedrate sche-duling strategies for free-form surfaces[J].International Journal of Machine Tools and Manufacture200646(7/8):747-757.
9 HUANG S, LI X, ZHAO Y,et al .A novel lapping process for single-crystal sapphire using hybrid nanoparticle suspensions[J].International Journal of Mechanical Sciences2021191:106099/1-12.
10 RIDWAN F, XU X,HO F .Adaptive execution of an NC program with feed rate optimization[J].International Journal of Advanced Manufacturing Technology201263:1117-1130.
11 WANG L, YUAN X, SI H,et al .Feedrate scheduling method for constant peak cutting force in five-axis flank milling process[J].Chinese Journal of Aeronautics202033(7):2055-2069.
12 WU S, ZHAO Z, WANG C,et al .Optimization of toolpath with circular cycle transition for sharp corners in pocket milling[J].International Journal Advanced Manufacturing Technology201686:2861-2871.
13 KIM H-C .Tool path modification for optimized pocket milling[J].International Journal of Production Research200745(24):5715-5729.
14 RAHMAN A A, FENG H-Y .Effective corner machining via a constant feed rate looping tool path[J].International Journal of Production Research201351(6):1836-1851.
15 MA J, SONG D, JIA Z,et al .Tool-path planning with constraint of cutting force fluctuation for curved surface machining[J].Precision Engineering201851:614-624.
16 HAN F, GU Z, HE L,et al .An optimization method of trochoidal radius for trochoidal milling hole based on the adaptive feed rate scheduling[J].The International Journal of Advanced Manufacturing Technology2024130(3):1527-1539.
17 WAGIH M, MAHER I, E-H HASSAN,et al .Analysis and development of elliptical tool path in trochoidal milling[J].CIRP Journal of Manufacturing Science and Technology202347:168-183.
18 OHTSU N .A threshold selection method from gray-level histograms[J].IEEE Transactions on Systems Man & Cybernetics19799(1):62-66.
19 WANG Q-H, WANG S, JIANG F,et al .Adaptive trochoidal toolpath for complex pockets machining[J].International Journal of Production Research201654(20):5976-5989.
Outlines

/