In multi-pass flank milling of thin-walled workpieces, deflections of both the workpiece and tool caused by the cutting force jeopardize the geometrical accuracy of the machined part, which is particularly problematic when cutting hard materials, such as titanium super-alloy used for blades on jet engines, as the due cutting force will be exceedingly large. Traditionally, to mitigate the deflection, machining parameters such as feed rate and depth-of-cut are set as constants and selected extremely conservatively, thus severely prolonging the total machining time. In this paper, aiming at reducing the total machining time while refraining the deflection of both the tool and in-process workpiece, we present a new multi-pass tool path generation method for flank milling of thin-walled workpieces at semi-finish and finish machining stages. In our method, both the feed rate and depth-of-cut are allowed to vary in each pass, and they are simultaneously maximized while subject to the given limits on the deflections of both the tool and in-process workpiece as well as the kinematical limits of the machine tool itself. A practical semi-greedy algorithm is then proposed to solve the formulated global optimization problem which includes both the finite element analysis for calculating the workpiece deflection and the meshing operation. Both computer simulation and physical cutting experiments are performed to demonstrate that a substantial saving (over 20%) in total machining time could be realized by the proposed method.

在薄壁工件的多道次侧面铣削中，切削力引起的工件和刀具的挠曲会危及被加工零件的几何精度，这在切削硬质材料时尤其成问题，例如用于切削加工的钛高温合金。喷气发动机上的叶片，因为应有的切割力将非常大。传统上，为了减轻挠度，加工参数如进给率和切削深度被设置为常数，并非常保守地选择，从而严重延长了总加工时间。在本文中，为了减少总加工时间，同时抑制刀具和加工中工件的偏转，我们提出了一种新的多道次刀具路径生成方法，用于薄壁工件的半精加工和精加工侧面铣削加工阶段。在我们的方法中，进给率和切削深度在每次通过时都允许变化，并且它们同时最大化，同时受到工具和加工中工件的偏转以及运动学的给定限制机床本身的局限性。然后提出了一种实用的半贪婪算法来解决公式化的全局优化问题，该问题包括计算工件挠度的有限元分析和网格划分操作。执行计算机模拟和物理切割实验以证明所提出的方法可以实现总加工时间的显着节省（超过 20%）。并且它们同时最大化，同时受到刀具和加工中工件挠度的给定限制以及机床本身的运动学限制。然后提出了一种实用的半贪婪算法来解决公式化的全局优化问题，该问题包括计算工件挠度的有限元分析和网格划分操作。执行计算机模拟和物理切割实验以证明所提出的方法可以实现总加工时间的显着节省（超过 20%）。并且它们同时最大化，同时受到刀具和加工中工件挠度的给定限制以及机床本身的运动学限制。然后提出了一种实用的半贪婪算法来解决公式化的全局优化问题，该问题包括计算工件挠度的有限元分析和网格划分操作。执行计算机模拟和物理切割实验以证明所提出的方法可以实现总加工时间的显着节省（超过 20%）。然后提出了一种实用的半贪婪算法来解决公式化的全局优化问题，该问题包括计算工件挠度的有限元分析和网格划分操作。执行计算机模拟和物理切割实验以证明所提出的方法可以实现总加工时间的显着节省（超过 20%）。然后提出了一种实用的半贪婪算法来解决公式化的全局优化问题，该问题包括计算工件挠度的有限元分析和网格划分操作。执行计算机模拟和物理切割实验以证明所提出的方法可以实现总加工时间的显着节省（超过 20%）。