基於粒子群演算法之五軸加工刀具軸向優化

Abstract

隨著數位控制銑床工具機的進步，自由曲面刀具路徑優化及切削力之控制已經成為了現代高精度加工領域中一項極具挑戰的問題。如何有效地進行刀具路徑優化，確保刀具的適切角度、降低加工時間、提高產品品質是目前加工製造業邁向智慧化的重要議題。對於刀具路徑而言，尋找最佳刀具方向(Tool orientation)，將有助於降低切削力、減少刀具磨損、提升產品的品質及加工效率。然而，路徑優化是非線性且高度受制約的最佳化問題，傳統的最佳化方法往往難以獲得理想的結果。 針對上述問題，本研究將提出一種基於粒子群最佳化（Particle Swarm Optimization，PSO）演算法的刀具路徑優化方法。利用 PSO 的全局搜尋能力和適合解決連續性最佳化問題之特點，通過建立加工過程中的切削力模型，結合圖形幾何計算和刀具路徑生成技術，針對銑削自由曲面過程中之刀具軸向進行優化。並將刀具角度優化問題轉化為一個多目標優化問題，經優化後可得低切削力且刀具軸向變動小之刀具路徑。 驗證結果顯示，本研究所提出的基於 PSO 演算法的刀具路徑優化方法，可以有效地使加工路徑平滑化及減少切削力。此方法也具有廣泛的應用前景，可適用於各種複雜形狀的自由曲面銑削。

With the advancement of digital control milling machine tools, the optimization of free-form tool paths and the control of cutting force have become a highly challenging problem in the field of modern high-precision machining. How to effectively optimize tool paths, ensure proper tool angles, reduce machining time, and improve product quality is an important topic as the manufacturing industry moves towards intelligence. In terms of tool paths, finding the optimal tool orientation can help reduce cutting forces, decrease tool wear, improve product quality, and increase machining efficiency. However, path optimization is a nonlinear and highly constrained optimization problem, and traditional optimization methods often struggle to achieve ideal results. In response to these issues, this study proposes a tool path optimization method based on the Particle Swarm Optimization (PSO) algorithm. By utilizing the global search capability of PSO and its suitability for solving continuous optimization problems, a cutting force model is established during the machining process. Combined with graphic geometric calculation and tool path generation techniques, the tool axis in the milling process of free surfaces is optimized. The tool angle optimization problem is transformed into a multi-objective optimization problem, and after optimization, a tool path with low cutting force and small tool axis variation can be obtained. Validation results show that the tool path optimization method based on the PSO algorithm proposed in this study can effectively smooth the machining path and reduce cutting forces. This method also has a wide range of application prospects and can be applied to the milling of various complex-shaped free surfaces. In the future, it will have practical value in actual production.