Tool Posture Planning Method for Low Rigidity Workpiece Considering Elastic Deformation Caused by Cutting Force

In machining process for a workpiece with low rigidity such as a blade shape, it is required to consider elastic deformation of the workpiece shape itself due to cutting force. Conventionally, reduction of the cutting force in machining process is achieved by optimization of feed rate value in NC program. On the other hand, since a decrease in the feed rate causes an increase in machining time. So, other optimization algorithm is required. In this paper, a new method to suppress the elastic deformation of the workpiece by changing tool posture in multi-axis controlled machining is proposed. The proposed method is intended for finish machining process for blade shape with a ball end mill. In the proposed method, first, the cutting force loaded on the workpiece surface in a certain posture candidate is predicted, and an instantaneous cutting force at the moment when the machining surface is generated is estimated by model-based computer simulation. Based on this results, the amount of elastic deformation on the machined surface is estimated by FEM. This process is repeated at each cutter location and tool posture candidate, and the new tool posture that can minimize machining error caused by the elastic deformation is determined at each cutter location.