The demand for optimization of manufacturing processes rises as a reflection of the highly competitive market environment that requires shorter lead time and lower production costs. Although some approaches to milling process optimization have been developed based on analytical model using average cutting parameters, they are not available for complex workpieces when cutting parameters are time-varying and instantaneous cutting conditions need to be considered. In order to automate the optimization process and avoid costly machining tests, in this paper, an effective approach for parameters optimization of complex end milling process based on virtual machining is proposed. A computer-aided design (CAD)/computer-aided manufacturing (CAM) application is integrated for actual tool path generation and feedrate scheduling based on material removal rate. Then, a machining simulator based on octree and instantaneous force model is developed to evaluate feasibility of the given numerical control (NC) program, and the correctness of this simulator is verified by machining tests. The optimization process is controlled by the efficient global optimization method to find global optimal solution with fewer simulations and less computation time. During each iteration of the optimization process, NC programs are generated and evaluated automatically by the CAD/CAM application and the simulator, respectively. The effectiveness and efficiency of the proposed approach are proved by comparing the generated optimal solution (has reduced machining time and production cost) with the recommended cutting parameters from machining experts when machining an impeller.

由于竞争激烈的市场环境要求缩短交货时间和降低生产成本，因此对制造工艺最优化的需求不断增加。尽管已经基于使用平均切削参数的分析模型开发了一些铣削工艺优化方法，但是当切削参数随时间变化并且需要考虑瞬时切削条件时，它们不适用于复杂的工件。为了使优化过程自动化并避免进行昂贵的机加工测试，本文提出了一种有效的基于虚拟加工的复杂立铣工艺参数优化的方法。集成了计算机辅助设计（CAD）/计算机辅助制造（CAM）应用程序，可根据材料去除率实际生成刀具路径和进给率。然后，开发了一种基于八叉树和瞬时力模型的加工模拟器，以评估给定数控程序的可行性，并通过加工测试验证了该模拟器的正确性。通过高效的全局优化方法控制优化过程，以找到具有更少仿真和更少计算时间的全局最优解。在优化过程的每次迭代过程中，NC程序分别由CAD / CAM应用程序和模拟器自动生成和评估。通过比较生成的最佳解决方案（减少了加工时间和生产成本）与加工专家在叶轮加工时推荐的切削参数，证明了该方法的有效性和效率。开发了一种基于八叉树和瞬时力模型的加工模拟器，以评估给定数控程序的可行性，并通过加工测试验证了该模拟器的正确性。优化过程由高效的全局优化方法控制，以找到仿真次数更少，计算时间更少的全局最优解。在优化过程的每次迭代过程中，NC程序分别由CAD / CAM应用程序和模拟器自动生成和评估。通过比较生成的最佳解决方案（减少了加工时间和生产成本）与加工专家在叶轮加工时推荐的切削参数，证明了该方法的有效性和效率。开发了一种基于八叉树和瞬时力模型的加工模拟器，以评估给定数控程序的可行性，并通过加工测试验证了该模拟器的正确性。优化过程由高效的全局优化方法控制，以找到仿真次数更少，计算时间更少的全局最优解。在优化过程的每次迭代过程中，NC程序分别由CAD / CAM应用程序和模拟器自动生成和评估。通过比较生成的最佳解决方案（减少了加工时间和生产成本）与加工专家在叶轮加工时推荐的切削参数，证明了该方法的有效性和效率。