Collision-free tool orientation optimization in five-axis machining of bladed disk

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Abstract

Bladed disk (BLISK) is a vital part in jet engines with a complicated shape which is exclusively machined on a five-axis machine and requires high accuracy of machining. Poor quality of tool orientation (e.g., false tool positioning and unsmooth tool orientation transition) during the five-axis machining may cause collision and machine vibration, which will debase the machining quality and in the worst case sabotage the BLISK. This paper presents a reference plane based algorithm to generate a set of smoothly aligned tool orientations along a tool path. The proposed method guarantees that no collision would occur anywhere along the tool path, and the overall smoothness is globally optimized. A preliminary simulation verification of the proposed algorithm is conducted on a BLISK model and the tool orientation generated is found to be stable, smooth, and well-formed.

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Chen, L., Xu, K., & Tang, K. (2015). Collision-free tool orientation optimization in five-axis machining of bladed disk. Journal of Computational Design and Engineering, 2(4), 197–205. https://doi.org/10.1016/j.jcde.2015.06.001

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