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toolpath optimization based on Sequential Quadratic Programming for five-axis flat-end milling with hybrid robots

JOURNAL OF MANUFACTURING PROCESSES 2025年 141卷 1619-1630页

作者： Zhang, Shiqi Ding, Ye Shanghai Jiao Tong Univ Sch Mech Engn State Key Lab Mech Syst & Vibrat Shanghai 200240 Peoples R China

Optimal toolpath generation is crucial for improving machining efficiency and surface finish quality. However, this task becomes challenging in the context of robotic flat-end milling, where both the contact geometry of cutters on free-form surfaces and robot kinematics need to be addressed. This paper introduces a toolpath optimization framework for flat-end milling with five-axis hybrid robots. The proposed method integrates joint path smoothness and machining width into the objective function, and it simultaneously optimizes the feed direction and tool orientation of the flat-end cutter by including feed angles, inclination angles, and tilt angles as optimization variables. The analytical gradient of the optimization problem is derived by applying differential geometry of surfaces. Based on this gradient derivation, Sequential Quadratic Programming is employed to efficiently solve the original nonconvex problem, resulting in an optimized toolpath that exhibits both improved path smoothness and increased machining width. Feedrate scheduling of the toolpath, which considers workspace and joint space constraints, demonstrates that machining time is reduced for hybrid robots characterized by highly nonlinear kinematics. Simulations and experimental validations further confirm the method's capability to enhance machining efficiency.

关键词： toolpath optimization Flat-end milling Sequential quadratic programming Hybrid robot

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toolpath optimization for high speed milling of pockets

Toolpath Optimization for high speed milling of pockets

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2nd International Conference on Information and Computing Science

作者： Zhao Zhenyu Liu Bai Zhang Meng Zhou Houming Yu Songsen Shenzhen Inst Informat Technol Shenzhen 518029 Peoples R China Xiangtan Univ Xiangtan 411105 Peoples R China

ISBN: (纸本)9780769536347

In milling pocket corner, there maybe residual material left at sharp corners when stepover is extremely large in contour-parallel toolpath. This paper describes an improved pocket toolpath by inserting biarc transitions segments in contour-parallel toolpath. When reaching the sharp corner, the cutter moves along the biarc transitions toolpath so that the corner material is removed. The efficient toolpath is continuous for clearing residual material at sharp corner. Milling test has been conducted to demonstrate and verify the significance of the proposed method.

关键词： HSM corner toolpath optimization

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Pocketing toolpath optimization for sharp corners

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JOURNAL OF MATERIALS PROCESSING TECHNOLOGY 2007年 192卷 175-180页

作者： Zhao, Z. Y. Wang, C. Y. Zhou, H. M. Qin, Z. GuangDong Univ Technol Guangzhou 510090 Peoples R China

In pocket milling. there may be residual material left at sharp corners when stepover is inappropriately large in contour-parallel tool paths. According to this problem, the paper proposes an improved NC toolpath generation strategy in order to optimize NC machining processes for pocket milling. By inserting two types of biarc transition segments in contour-parallel toolpaths, the new method can remove the residual material completely without cutter compensation, produce second order continuous toolpath, and allow the stepover to be as wide as possible to reduce the machining time. A machining experiment has been implemented to validate the efficiency of the method. (c) 2007 Published by Elsevier B.V.

关键词： HSM comer toolpath optimization

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An efficient 5-axis toolpath optimization algorithm for machining parts with abrupt curvature

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PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE 2017年第9期231卷 1609-1621页

作者： Qin, Ji-Yun Jia, Zhen-Yuan Ma, Jian-Wei Ren, Zong-Jin Song, De-Ning Dalian Univ Technol Minist Educ Key Lab Precis & Nontradit Machining Technol Dalian 116024 Peoples R China

The kinematical behavior of 5-axis machine tool introduced by toolpath calculation has a close relation with processing efficiency and quality of parts. For the category of sculptured surface parts with abrupt curvature, such as turbine blade and fixed guide vane, the most commonly utilized spiral contouring toolpath modes usually encounter some trouble during actual machining, the reason lies in the difficult tool orientation control near the edge of such parts. However, the global optimization for the spiral toolpath means increased computation burden, and so it is time consuming. In this paper, an efficient 5-axis toolpath optimization algorithm is presented, and the objective is to smooth the rotary axes' motion caused by drastically changed tool orientation on spiral toolpath for abrupt curvature parts machining. To reduce the computation burden, only path segments on the spiral trajectory-owned weak kinematic performance are selected for further optimizing. To obtain smoother motion for rotary axes, the specific optimization computation for the selected path segments is conducted in the Machine Coordinate System (MCS) instead of the Part Coordinate System (PCS). The optimization model is constructed and a related solution method is presented to ensure the high-performance optimization. The complete optimization algorithm is demonstrated on a spiral 5-axis toolpath for the turbine blade finish machining, and the result shows that only 25.9% optimization computation is needed compared with global optimization algorithm. And then, the actual machining experiments are carried out by using paraffin as cut material, and the machining time with optimized toolpath is decreased by 19.7% compared with initial toolpath. In addition, the surface quality of parts is significantly improved after conducting the optimization. This study proves that the proposed algorithm can significantly improve the processing efficiency and surface quality of parts with abrupt curvature and

关键词： 5-Axis machine tool kinematical performance spiral trajectory abrupt curvature toolpath optimization computation burden

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Process modeling and toolpath optimization for five-axis ball-end milling based on tool motion analysis

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INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY 2011年第9-12期57卷 905-916页

作者： Zhang, Liqiang Shanghai Univ Engn Sci Coll Mech Engn Shanghai 201620 Peoples R China

In free-form surface machining, the prediction of five-axis ball-end milling forces is quite a challenge due to difficulties of determining the underformed chip thickness and engaged cutting edge. Part and tool deflections under high cutting forces may result in poor part quality. To solve these concerns, this paper presents process modeling and optimization method for five-axis milling based on tool motion analysis. The method selected for geometric stock modeling is the dexel approach, and the extracted cutter workpiece engagements are used as input to a force prediction. The cutter entry-exit angles and depth of cuts are found and used to calculate the instantaneous cutting forces. The process is optimized by varying the feed as the tool-workpiece engagements vary along the toolpath, and the unified model provides a powerful tool for analyzing five-axis milling. The new feedrate profiles are shown to considerably reduce the machining time while avoiding process faults.

关键词： Five-axis Process modeling toolpath optimization Kinematics analysis

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Pocketing toolpath optimization for sharp corners

Pocketing toolpath optimization for sharp corners

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7th Asia Pacific Conference on Materials Processing (APCMP 2006)

作者： Zhao, Z. Y. Wang, C. Y. Zhou, H. M. Qin, Z. GuangDong Univ Technol Guangzhou 510090 Peoples R China

关键词： HSM comer toolpath optimization

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A multi-layer approach for additive manufacturing of continuous fiber composites

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POLYMER COMPOSITES 2025年第4期46卷 3623-3635页

作者： Tawfik, Hussam Goldsmith, Peter Univ Calgary Schulich Sch Engn Dept Mech Engn Calgary AB Canada

Additive manufacturing (AM) of continuous fiber reinforced polymer composites (cFRPCs) requires innovative tool-pathing strategies that account for the anisotropic properties of the continuous fibers and ensure their continuous deposition as reinforcement along the designed structure, reducing fibers bending and cutting. Existing 3D printing slicing software, designed for isotropic materials like neat polymers, has been adapted for 3D printing of continuous fiber composites, resulting in a layer-by-layer approach that necessitates filament cutting after each layer deposition. This method introduces discontinuities, weakening the material and underutilizing continuous fibers strength. In this research, we propose a novel tool-pathing strategy designed to address these challenges through (1) Ensuring fiber continuity across layers by allowing overlapping filaments and (2) Strategically positioning fiber cut points based on stress distribution, modeled using finite element analysis. A Multi-Layer Continuous Fiber Path (ML-CFP) approach was introduced and validated on a simple bracket structure featuring two load-application inserts. 3D printed brackets using different tool paths were tested to failure under tension and compression after compression molding to improve interlayer adhesion. Mechanical investigations confirmed that the ML-CFP approach enhances fiber utilization, improving tensile strength and work to fracture by up to 46% and 100% through promoting failure in fibers rather than at cut *** Introduced the multi-layer continuous fiber path method (ML-CFP) in AM of cFRPCs. Introduced the strategic cut point placement (SCPP) based on stress distribution. Maintaining fiber continuity and reduce fiber bending by allowing filament overlap. Mechanical testing to compare the ML-CFP with conventional slicing methods. Enhanced tensile strength by up to 46% and work to fracture by 100%.

关键词： continuous carbon fiber fiber steering fused filament fabrication (FFF) toolpath optimization

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toolpath Generation for Robotic Flank Milling via Smoothness and Stiffness optimization

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ROBOTICS AND COMPUTER-INTEGRATED MANUFACTURING 2024年 85卷

作者： Chen, Yongxue Lu, Yaoan Ding, Ye Shanghai Jiao Tong Univ Sch Mech Engn State Key Lab Mech Syst & Vibrat Shanghai 200240 Peoples R China Guangdong Univ Technol Sch Electromech Engn Guangzhou 510006 Peoples R China

Robotic flank milling has outstanding advantages in machining large-scale slender surfaces. Currently, the paths for this process are mainly generated by optimizing redundant robot degrees of freedom (DoFs) on the basis of conventional 5-axis flank milling paths. This two-step framework, however, does not enable optimal robot kinematic and dynamical performance compared to the direct generation of 6-DoF robot paths, limiting the machining efficiency and effectiveness. This paper presents an optimization method to directly generate a toolpath with six DoFs for robotic flank milling. Firstly, the kinematic model of the milling system and the representation of the 6-DoF toolpath are established. Then, the standard geometric error for flank milling that conforms to the geometric specification is defined, and an efficient algorithm based on conformal geometric algebra is proposed to solve it. On this basis, the toolpath optimization model with toolpath smoothness and robot stiffness as objective functions is established. A sequential quadratic programming algorithm is proposed to solve this highly non-linear problem based on the lexicographic order of arrays. The simulations and experiments demonstrate that the proposed method has better efficiency, robustness, and effectiveness compared with the existing methods. Due to the improvement of smoothness and stiffness, the productivity, accuracy, and finish of the machining are all enhanced.

关键词： Robotic milling toolpath optimization Flank milling Sequential quadratic programming

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A Review of Multi-holes Drilling Path optimization Using Soft Computing Approaches

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ARCHIVES OF COMPUTATIONAL METHODS IN ENGINEERING 2019年第1期26卷 107-118页

作者： Abidin, Najwa Wahida Zainal Ab Rashid, Mohd Fadzil Faisae Mohamed, Nik Mohd Zuki Nik Univ Malaysia Pahang Fac Mech Engn Pekan 26600 Pahang Malaysia

In today's competitive environment, optimization is considered as an important element for maintaining and improving both aspect of manufacturing such as quality and productivity. In multi-holes drilling process, 70% of the machining time involved the tool movement and tool switching. Various researches had been conducted to reduce the tool movement and switching time. This paper reviews the research publications on the drilling path optimization using soft computing approaches. In particular, this review focuses on four main aspects;drilling application areas, problem modeling, optimization algorithms and objective functions of drilling path optimization. Based on the review, the researchers' interest in this area is still growing. However, the existing researches were limited to implement, modify and hybridized the well-established optimization algorithms. Furthermore, there is a lack of awareness to consider the environmental and sustainable issues in the existing research. In future, the researcher is suggested to give focus on energy consumption that related with sustainable manufacturing and also to explore the potential of new meta-heuristics algorithms that can lead to significant in reduction machining time.

关键词： Drilling process toolpath optimization Soft computing

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Perspectives on a BIM-integrated software platform for robotic construction through Contour Crafting

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AUTOMATION IN CONSTRUCTION 2018年 89卷 13-23页

作者： Davtalab, Omid Kazemian, Ali Khoshnevis, Behrokh Univ Southern Calif Sonny Astani Dept Civil & Environm Engn Los Angeles CA USA Univ Southern Calif Dept Comp Sci Los Angeles CA 90007 USA Univ Southern Calif Dept Ind & Syst Engn Los Angeles CA USA

Robotic construction through concrete 3D printing is an in-progress revolution in construction industry. While significant progress is made on hardware related challenges, software and information related issues of such innovative system are less discussed. In this paper, a software platform is proposed for data retrieval and analysis from BIM models and utilizing it efficiently during various stages of the process. While the general idea of using BIM for automated construction has been mentioned before, the implementation details (the focus of this paper) were not previously discussed. To this aim, a framework is proposed to integrate BIM into an automated construction system. A Planning and Operations Control Software for Automated Construction (POCSAC) is developed as a major enabler for a seamless integration of BIM and Contour Crafting. The interoperation between different components of the construction system and BIM platform are designed to maximize the realized benefits through synergy of the two technologies.

关键词： Software platform BIM 3D printing Automated construction toolpath optimization Robotic control Contour Crafting

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