Simultaneous optimization of the feed direction and tool orientation in five-axis flat-end milling
针对五轴平底铣削，提出同步优化进给方向和刀具姿态的模型，以最大化加工宽度并避免局部过切，提高自由曲面加工效率。
The two additional rotational motions of five-axis machining make the determination of the optimal feed direction and tool orientation a challenging task. A new model to find the optimal feed direction and tool orientation maximising the machining width and avoiding local gouging at a cutter contact (CC) point with a flat-end cutter considering the tool path smoothness requirement is developed in this paper. The machining error is characterised by a signed distance function defined from a point on the bottom tool circle of the cutter to the design surface. With the help of the differential evolution approach, the optimisation model can be resolved to determine the optimal tool orientation and feed direction at a given CC point, and generate the smooth tool paths following the optimal feed direction. Simulation examples demonstrate the developed techniques can improve the tool orientation and feed direction at a CC point to increase the machining width, improving the efficiency of freeform surface machining.