Optimization of disc tool parameters and tool path of five-axis milling of twist channels

In this paper, we focus on the issue of the rough machining of twist channels with disc tools. First, a synchronous planning method of disc milling cutter parameters and tool path is proposed to achieve the large material removal volume in single-pass milling process as well as generate the interference-free tool path. Local tool parameters and feasible tool orientation respecting the geometric constraints are iteratively searched with the aid of machining feasible space (MFS) construction. Then, local optimal tool parameters as well as feasible orientation can be determined according to the evolution principle of width and radius of the disc tool. Subsequently, global optimal tool parameters can be determined and the optimal tool path can be acquired by the tool orientation smoothing with the minimum C-distance. Although the tool path has been successfully smoothed in WCS, the performance of drive axes may not be guaranteed. To address this issue, a local smoothing method with interference and drive constraints for tool orientation planning is developed. By transforming the problem of tool orientation smoothness with interference-free and drive constraints into the least-square optimal problem with interference-free constraint, the optimal tool orientation can be obtained by a two-step method. The numerical results verified the effectiveness of the proposed method.