Energy-Efficient Cutting Parameters Determination for NC Machining with Specified Machining Accuracy

An energy-efficient cutting parameters determination method for NC machining parts with specified machining accuracy is proposed in this paper. The identification mechanism of machine tool errors by R-test is employed to establish machining error estimation model. By replacing the coordinate of each tool path point with the origin, the R-test tool paths are generated. R-tests at two different setups are designed to capture the volumetric errors of the machine tool. After dynamic R-test simulations at different feedrates in two setups, the volumetric errors of the machine tool at different feedrates are predicted. With the volumetric errors, the maximum machining errors of the part at different feedrates are calculated based on the machining error estimation model. The allowed feedrate range is obtained by comparing the calculated machining errors with the specified machining accuracy. With the allowed feedrate range and the other cutting parameters as the factors, the response surface of total energy consumption of machine tool is constructed according to the requirements of machining operations. The energy-efficient cutting parameters combination is found by searching the constructed response surface. A typical aircraft structural part is used to validate the proposed method.