Allowance distribution and parameters optimization for high-performance machining of low rigidity parts in multistage machining processes

doi:10.1007/s40436-024-00520-1

Advances in Manufacturing ›› 2025, Vol. 13 ›› Issue (3): 584-605.doi: 10.1007/s40436-024-00520-1

• • 上一篇

Allowance distribution and parameters optimization for high-performance machining of low rigidity parts in multistage machining processes

Hao Sun^1,2, Sheng-Qiang Zhao¹, Fang-Yu Peng^1,2,3, Rong Yan¹, Xiao-Wei Tang¹

1. School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, People's Republic of China;
2. Wuhan Digital Design and Manufacturing Innovation Center Co. Ltd, Wuhan, 430074, People's Republic of China;
3. State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, 430074, People's Republic of China

收稿日期:2023-11-30 修回日期:2024-01-17 发布日期:2025-09-19
通讯作者: Fang-Yu Peng,E-mail:pengfy@hust.edu.cn E-mail:pengfy@hust.edu.cn
作者简介:Hao Sun received his Ph.D. degree in mechanical engineering from Huazhong University of Science and Technology in 2023. He is now a postdoctoral fellow at Huazhong University of Science and Technology and Wuhan Digital Design and Manufacturing Innovation Center Co., LTD. Besides, he is now the Deputy Director of Manufacturing and Inspection Center of Wuhan Digital Design and Manufacturing Innovation Center Co., LTD. His research focuses on intelligent manufacturing and high-precision five-axis CNC machining.
Sheng-Qiang Zhao received the B.S. degree from Huazhong University of Science and Technology in 2019. He is currently a Ph.D. degree candidate at the School of Mechanical Science and Engineering of Huazhong University of Science and Technology. His research interests include robotic machining posture and trajectory planning, machining precision prediction and control.
Fang-Yu Peng received the B.S. and Ph.D. degrees in mechanical engineering from the Huazhong University of Science and Technology in 1994 and 2000, respectively. In January 2004, he joined the National NC System Engineering Research Center as a deputy director. In June 2006, he worked as a visiting researcher in FTC in Japan. In March 2007, he was seconded to Department of Engineering and Material Science, National Natural Science Foundation of China, as director of mechanical project. In July 2014, he worked as Deputy director of National NC System Engineering Research Center. His research focuses on robot processing and high-precision five-axis CNC machining.
Rong Yan received the Ph.D. degree in mechanical engineering from the Wuhan University in 2005. From 2005 to 2007, she worked as a postdoctoral fellow in Huazhong University of Science and Technology. Since 2011, she has been with School of Mechanical Science and Engineering in Huazhong University of Science and Technology. She is currently full professor and Ph.D. supervisor of National NC System Engineering Research Center in Huazhong University of Science and Technology. Her research has focused on machining surface integrity and multi-axis machining accuracy compensation.
Xiao-Wei Tang received the B.S. degree in mechanical engineering from Southwest Jiaotong University in 2008 and his M.S. degree from Wuhan University of Technology in 2011. In 2017, he received the Ph.D. degree in mechanical engineering from Huazhong University of Science and Technology, Wuhan, China. He engaged in teaching and scientific research since 2019. His research focuses on modeling of multi-axis machining dynamics, robot milling processing technology and equipment development.
基金资助:
This research was financially supported by the National Science and Technology Major Project of China (Grant No. J2019-VII-0001-0141), and the National Natural Science Foundation of China (Grant No. 92160301).

Allowance distribution and parameters optimization for high-performance machining of low rigidity parts in multistage machining processes

Hao Sun^1,2, Sheng-Qiang Zhao¹, Fang-Yu Peng^1,2,3, Rong Yan¹, Xiao-Wei Tang¹

1. School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, People's Republic of China;
2. Wuhan Digital Design and Manufacturing Innovation Center Co. Ltd, Wuhan, 430074, People's Republic of China;
3. State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, 430074, People's Republic of China

Received:2023-11-30 Revised:2024-01-17 Published:2025-09-19
Supported by:
This research was financially supported by the National Science and Technology Major Project of China (Grant No. J2019-VII-0001-0141), and the National Natural Science Foundation of China (Grant No. 92160301).

摘要/Abstract

摘要： There are a large number of low rigidity parts in the aerospace field, and how to achieve high-performance manufacturing in their multistage machining processes has received increasing attention. Optimizing the distribution of machining allowance and machining parameters is one of the most convenient ways to improve the machining performance of these parts. In this paper, firstly, considering the machining accuracy and machining efficiency comprehensively, the error efficiency cooperation coefficient of low rigidity parts during machining is established. Based on the semi-parametric regression theory and measured data, the machining error transfer factor within the cooperation coefficient is calibrated. Secondly, the machining optimization strategy based on the Bayesian framework is proposed, and the optimization of multiple machining parameters is realized with the goal of minimizing the error efficiency cooperation coefficient. Finally, the optimization software of machining processes of low rigidity parts for engineering application is developed. In the verification experiments of blade parts, the error efficiency cooperation coefficient is reduced to 0.032 1 after optimization, and the average improvement of machining errors of all measured points is 14.31 μm. Besides, the above method is applied to low rigidity shaft parts, and the effectiveness of the proposed method is further verified.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00520-1

关键词: Machining allowance distribution, Machining parameters optimization, High-performance machining, Low rigidity parts, Multistage processes

Abstract: There are a large number of low rigidity parts in the aerospace field, and how to achieve high-performance manufacturing in their multistage machining processes has received increasing attention. Optimizing the distribution of machining allowance and machining parameters is one of the most convenient ways to improve the machining performance of these parts. In this paper, firstly, considering the machining accuracy and machining efficiency comprehensively, the error efficiency cooperation coefficient of low rigidity parts during machining is established. Based on the semi-parametric regression theory and measured data, the machining error transfer factor within the cooperation coefficient is calibrated. Secondly, the machining optimization strategy based on the Bayesian framework is proposed, and the optimization of multiple machining parameters is realized with the goal of minimizing the error efficiency cooperation coefficient. Finally, the optimization software of machining processes of low rigidity parts for engineering application is developed. In the verification experiments of blade parts, the error efficiency cooperation coefficient is reduced to 0.032 1 after optimization, and the average improvement of machining errors of all measured points is 14.31 μm. Besides, the above method is applied to low rigidity shaft parts, and the effectiveness of the proposed method is further verified.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00520-1

Key words: Machining allowance distribution, Machining parameters optimization, High-performance machining, Low rigidity parts, Multistage processes

Hao Sun, Sheng-Qiang Zhao, Fang-Yu Peng, Rong Yan, Xiao-Wei Tang. Allowance distribution and parameters optimization for high-performance machining of low rigidity parts in multistage machining processes[J]. Advances in Manufacturing, 2025, 13(3): 584-605.

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Allowance distribution and parameters optimization for high-performance machining of low rigidity parts in multistage machining processes

Allowance distribution and parameters optimization for high-performance machining of low rigidity parts in multistage machining processes

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