Optimized tool path planning for five-axis flank milling of ruled surfaces using geometric decomposition strategy and multi-population harmony search algorithm

Abstract Tool path planning is a key to ensure high machining quality and productivity in 5-axis flank milling of ruled surfaces. Previous studies have shown that optimization-driven tool path planning can effectively reduce the geometrical errors on the finished surface. However, to solve the corresponding optimization problem is a challenging task involving a large number of decision variables. This paper proposes a novel approach to generating optimized tool path for 5-axis flank finishing cut based on a geometric decomposition strategy and multi-population harmony search algorithm. The proposed approach geometrically divides the surface to be machined into a number of segments. The tool paths on those sub-surfaces are independently optimized by the multi-population harmony search algorithm. Individual tool paths are then combined together to form a complete one. The test results of representative surfaces show that the proposed approach produces higher machining precision with less computational time than compared previous methods. And the computational time is further reduced by Message passing interface based parallel computing techniques. A detailed analysis is conducted to characterize how the number of divisions affects the optimization results. And the proposed approach also shows good scalability with the increasing number of cutter locations.