High-efficiency five-axis plunge milling technology with double-row slotting for integral impellers

Abstract

Plunge milling, which is recognized for its efficiency, has gradually been adopted for the roughing of integral impellers in recent years. However, several challenges persist, such as redundant tool paths, difficulties in managing the Sudden Increase of Radial Depth (SIRD), and excessive residual material in the adjusted tool path by plunge milling, which collectively constrain the efficiency of the plunge milling process. To address these challenges, this study proposes a five-axis plunge milling method with double-row slotting tailored for integral impellers. This method segments the machining area based on the width of the impeller runner and utilizes various tools with different diameters to enhance machining efficiency. The plunge milling path is optimized to facilitate efficient material removal while maintaining cutting stability, which addresses issues related to cutting overload and chip accumulation. In addition, an efficient method for SIRD identification and exclusion is proposed to minimize residual material. Simulation and practical machining results confirm that the proposed plunge milling method with double-row slotting significantly improves machining efficiency, which achieves enhancements of over 1.5 times compared with traditional methods.

Graphical abstract

Keywords

integral impeller / plunge milling / tool path / double-row slotting / residual material

References

[1] Radgolchin M, Anbarsooz M. Fatigue failure of centrifugal compressor impellers: A comprehensive review. Engineering failure analysis, 2023, 153: 107592

[2] Wang T, Xiang R, Yu H, Zhou M. Performance improvement of forward-curved impeller with an adequate outlet swirl using in centrifugal pump as turbine. Renewable Energy, 2023, 204: 67–76

[3] Ji L L, Li W, Shi W D, Chang H, Yang Z Y. Energy characteristics of mixed-flow pump under different tip clearances based on entropy production analysis. Energy, 2020, 199: 117447

[4] Nápoles Alberro A, González Rojas H A, Sánchez Egea A J, Hameed S, Peña Aguilar R M. Model based on an effective material-removal rate to evaluate specific energy consumption in grinding. Materials, 2019, 12(6): 939

[5] Heo E Y, Kim D W, Kim B H, Jang D K, Chen F F. Efficient rough-cut plan for machining an impeller with a 5-axis NC machine. International Journal of Computer Integrated Manufacturing, 2008, 21(8): 971–983

[6] Bo P B, Fan H Y, Bartoň M. Efficient 5-axis CNC trochoidal flank milling of 3D cavities using custom-shaped cutting tools. Computer-Aided Design, 2022, 151: 103334

[7] Bo P B, González H, Calleja A, de Lacalle L N L, Bartoň M. 5-axis double-flank CNC machining of spiral bevel gears via custom-shaped milling tools––Part I: Modeling and simulation. Precision Engineering, 2020, 62: 204–212

[8] Escudero G G, Bo P B, González-Barrio H, Calleja-Ochoa A, Bartoň M, de Lacalle L N L. 5-axis double-flank CNC machining of spiral bevel gears via custom-shaped tools––Part II: physical validations and experiments. The International Journal of Advanced Manufacturing Technology, 2022, 119(3–4): 1647–1658

[9] Elber G, Cohen E. Toolpath generation for freeform surface models. Computer-Aided Design, 1994, 26(6): 490–496

[10] Kim B H, Choi B K. Guide surface based tool path generation in 3-axis milling: an extension of the guide plane method. Computer-Aided Design, 2000, 32(3): 191–199

[11] Chu C H, Chen H Y, Chang C H. Continuity-preserving tool path generation for minimizing machining errors in five-axis CNC flank milling of ruled surfaces. Journal of Manufacturing Systems, 2020, 55: 171–178

[12] Chu C H, Wu P H, Lei W T. Tool path planning for 5-axis flank milling of ruled surfaces considering CNC linear interpolation. Journal of Intelligent Manufacturing, 2012, 23(3): 471–480

[13] Elber G, Cohen E, Drake S. MATHSM: medial axis transform toward high speed machining of pockets. Computer-Aided Design, 2005, 37(2): 241–250

[14] Rauch M, Duc E, Hascoet J Y. Improving trochoidal tool paths generation and implementation using process constraints modelling. International Journal of Machine Tools & Manufacture, 2009, 49(5): 375–383

[15] Santhakumar J, Iqbal U M. Role of trochoidal machining process parameter and chip morphology studies during end milling of AISI D3 steel. Journal of Intelligent Manufacturing, 2021, 32(3): 649–665

[16] Feng J Y, Wei Z C, Wang M J, Wang X Q, Guo M L. Tool path planning for five-axis U-pass milling of an impeller. The International Journal of Advanced Manufacturing Technology, 2021, 117(11–12): 3379–3391

[17] Wakaoka S, Yamane Y, Sekiya K, Narutaki N. High-speed and high-accuracy plunge cutting for vertical walls. Journal of Materials Processing Technology, 2002, 127(2): 246–250

[18] Huang N D, Krebs E, Baumann J, Zhou Y S, Wu S J, Biermann D. Experimental investigation on influence of engagement angle and tool geometry on plunge milling. The International Journal of Advanced Manufacturing Technology, 2020, 108(5–6): 1973–1981

[19] ShanC WZhang D HRenJ XHuC G. Research on the plunge milling techniques for open blisks. Materials Science Forum, 2006, 532–533: 193–196

[20] Ren J X, Yao C F, Zhang D H, Xue Y L, Liang Y S. Research on tool path planning method of four-axis high-efficiency slot plunge milling for open blisk. The International Journal of Advanced Manufacturing Technology, 2009, 45(1–2): 101–109

[21] Liang Y S, Zhang D H, Chen Z Z C, Ren J X, Li X Y. Tool orientation optimization and location determination for four-axis plunge milling of open blisks. The International Journal of Advanced Manufacturing Technology, 2014, 70(9–12): 2249–2261

[22] Dong J S, Chang Z Y, Chang Y, Chen Z Z C, Wan N. A novel approach to modeling of multi-axis plunge milling and its application on the simulation of complex part plunging. The International Journal of Advanced Manufacturing Technology, 2019, 102(5–8): 1141–1151

[23] Liang Y S, Ren J X, Zhang D H, Li X Y, Zhou J H. Mechanics-based feedrate scheduling for multi-axis plunge milling. The International Journal of Advanced Manufacturing Technology, 2015, 79(1–4): 123–133

[24] Zhang Y, Zhang D H, Han F Y. An approach to tool path planning for layered plunge milling of free-form surface impeller channel. International Journal of Manufacturing Research, 2017, 12(1): 131–144

[25] Guo K, Liu X L, Jiang Z P, Li W D, Huang J C. The key process technology research of open impeller processing. Materials Science Forum, 2012, 723: 450–455

[26] Han F Y, Zhang D H, Luo M, Wu B H. Optimal CNC plunge cutter selection and tool path generation for multi-axis roughing free-form surface impeller channel. The International Journal of Advanced Manufacturing Technology, 2014, 71(9–12): 1801–1810

[27] Wang X Q, Wei Z C, Wang D, Zhang D B, Wang X Y, Wang M J. A supplementary processing method of residual material in impeller plunge milling. Journal of Manufacturing Processes, 2023, 108(1): 1–11

[28] Sun C, Bi Q Z, Wang Y H, Huang N D. Improving cutter life and cutting efficiency of five-axis plunge milling by simulation and tool path regeneration. The International Journal of Advanced Manufacturing Technology, 2015, 77(5–8): 965–972

[29] Dong L, Wang J. A study of interferential tool position correcting algorithms in 3D impeller variable-axis rough plunge milling. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2023, 237(1–2): 122–133

[30] Elber G, Fish R. 5-axis freeform surface milling using piecewise ruled surface approximation. Journal of Manufacturing Science and Engineering, 1997, 119(3): 383–387

[31] Du S J, Surmann T, Webber O, Weinert K. Formulating swept profiles for five-axis tool motions. International Journal of Machine Tools & Manufacture, 2005, 45(7–8): 849–861

[32] Chen Z Z C, Khan M A. A new approach to generating arc length parameterized NURBS tool paths for efficient three-axis machining of smooth, accurate sculptured surfaces. The International Journal of Advanced Manufacturing Technology, 2014, 70(5–8): 1355–1368

[33] Chen S S, Cheung C F, Zhang F H, Liu M Y. Optimization of tool path for uniform scallop-height in ultra-precision grinding of free-form surfaces. Nanomanufacturing and Metrology, 2019, 2(4): 215–224

[34] Efkolidis N, Hernández C G, Talón J L H, Kyratsis P. Modelling and prediction of thrust force and torque in drilling operations of AI7075 using ANN and RSM methodologies. Journal of Mechanical Engineering, 2018, 64(6): 351–361

RIGHTS & PERMISSIONS

Higher Education Press