Tool orientation optimization method based on ruled surface using genetic algorithm

In five-axis machining, tool orientation optimization is a critical problem that significantly affects machining quality, efficiency, and kinetic performance. In this paper, a tool orientation optimization method based on ruled surface is proposed. Through optimizing section selection algorithm, the region to be optimized is selected precisely, and a ruled surface is established at each cutter contact point (CC point). The tool orientation optimization range is limited to a certain level, and optimization objective function is set to minimize the vibration of rotary axes. The proposed method is of advantages over existing methods in three aspects. First, the influence on machining area and surface quality can be reduced to a lower level due to the tool orientation change is limited to a certain surface. Second, the efficiency of optimization algorithm is improved. Third, the nonlinear mapping between tool orientation and rotary axes position is avoided by setting the kinetic parameters of the rotary axes as optimization goal. Simulation and experiment are performed to verify the performance of the proposed method.