Multi-tool Optimization Milling Method for Complex Cavities Based on Tool Allowable Loads

doi:10.3969/j.issn.1004-132X.2025.05.010

Abstract

Abstract: For 2.5D complex cavity CNC rough milling， the existing tool combination selection methods might not adequately consider the actual allowable loads of the tool， and the cutting load changed abruptly when machining with a contour-parallel tool path， which was easy to lead to chipping and tool breakage， affecting the safety and efficiency of rough milling. Therefore， a multi-tool optimization milling method was proposed for complex cavities based on tool allowable loads. An optimization model for milling efficiency with tool allowable loads as the constraint was established， and the optimal tool combination was selected from the available tool sets based on genetic algorithm. According to the selected tool combination， an adaptive machining area division method for complex cavities and a trochoidal and contour-parallel hybrid tool path generation method for multi-tool machining were given. A 2.5D complex cavity rough milling as the object of case analysis， under the tool allowable load constraints the optimal tool combination was selected and the combination of trochoidal and contour-parallel tool path was generated. Finally， the machining comparison results with the trochoidal milling method of NX software shows that the machining efficiency of the proposed method is improved by 25.9%， and the changes of machine loads are smooth during the machining processes， which verifies that the proposed multi-tool optimization milling method is feasible and effective.

Key words: , CNC milling, complex cavity, tool allowable load, optimized selection of tool combination, trochoidal and contour-parallel hybrid tool path

摘要： 对于2.5D复杂型腔数控铣削粗加工，现有刀具组合优选方法未充分考虑刀具的实际许用载荷，且采用环切刀轨加工时切削载荷会突变，易导致崩刃、断刀，影响铣削粗加工的安全性和效率，为此，提出了一种基于刀具许用载荷的复杂型腔多刀具优化铣削方法。建立了以刀具许用载荷为约束的铣削加工效率优化模型，并基于遗传算法从可用刀具集中选取最优刀具组合；根据所选刀具组合，给出了复杂型腔自适应加工区域划分方法及多刀具加工摆线-环切混合刀轨生成方法；以某2.5D复杂型腔零件铣削粗加工为对象进行算例分析，在刀具许用载荷约束下选取了最优刀具组合并生成了摆线-环切混合刀轨；最后与NX软件的摆线铣削方法进行加工对比验证，结果表明，所提方法的加工效率提高了25.9%，加工过程中机床负载变化平稳，验证了所提多刀具优化铣削方法可行且有效。

关键词: 数控铣削, 复杂型腔, 刀具许用载荷, 刀具组合优选, 摆线-环切混合刀轨

CLC Number:

TH164

HAN Feiyan, ZHAO Yipeng, LI Hongyang, ZHANG Hao, WANG Che, PENG Xianlong, ZHANG Chuanwei. Multi-tool Optimization Milling Method for Complex Cavities Based on Tool Allowable Loads[J]. China Mechanical Engineering, 2025, 36(05): 986-994.

韩飞燕, 赵一鹏, 李洪阳, 张浩, 王彻, 彭先龙, 张传伟. 基于刀具许用载荷的复杂型腔多刀具优化铣削方法[J]. 中国机械工程, 2025, 36(05): 986-994.

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