Virtual Five-Axis Flank Milling of Jet Engine Impellers-Part II: Feed Rate Optimization of Five-Axis Flank Milling  

Oleh:

Ferry, W. B. ; Altintas, Y.

Jenis: Article from Journal - ilmiah internasional
Dalam koleksi: Journal of Manufacturing Science and Engineering vol. 130 no. 1 (Feb. 2008), page 1-13.
Topik: Five-Axis Flank Milling; Jet Engine Impellers

Ketersediaan

Perpustakaan Pusat (Semanggi) Nomor Panggil: JJ93.11 Non-tandon: 1 (dapat dipinjam: 0) Tandon: tidak ada

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Isi artikel

This paper presents process optimization for the five-axis flank milling of jet engine inpellers based on the mechanics model explained in Part I. This process is oprimized by varying the feed automatically as the tool-workpiece engagements, i.e., the process, vary along the tool path. The feed is adjusted by limiting the feef-fepenfent peak outputs to a set of user-defined constraints. The constraints are the tool shank bending stress, tool deflection, maximum chip load (to avoid edge chipping), and the torgue limit of the machine. The linear and angular feeds of the tool are optimized by the two different methods- a multiconstraints based virtual adaptive control of the process and a nonlinear root-finding algorithm. The five-axis milling process is simulated in a virtual environment, and the resulting process outputs are stored at each position along the tool path. The process is recursively fitted to a first-order process with a time-varying gain and a fixed time constant, and a simple proportional-integral controller is adaptively turned to operate machine at threshold levels by manipulating the feed rate. As an alternative to the virtual adaptive process control, the feed rate is optomized by a nonlinear root-finding algorithm. The virtual cutting process is modeled as a black box function of feed and the optimum feed is solved for iteratively, respecting tool stress, tool deflection, torque, and chip load constraints. Both methods are shown to produce almost identical optimized feed rate profiles for the roughing tool path discussed in Paper I. This new feed rate profiles are shown to considerably reduce the cycle time of the impeller while avoiding process faults that may damage the part of the machine.

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