Key Takeaways & Executive Findings
- •• Identifies unreasonable tool path planning as the root cause of SIRD in five-axis plunge milling. • Develops an SIRD discrimination model using cutter position and axis vector as variables. • Optimized tool path reduces residual material volume to less than 60% of gradually decreasing plunge depth. • Enhances machining efficiency and enables automated tool path optimization without operator experience.
Abstract
A sudden increase in the radial depth (SIRD) is a distinctive phenomenon in plunge milling. It is typically characterized by a sharp increase in cutting force at the end of the axial feed of the tool, accompanied by harsh machine vibration sounds, which can negatively impact the reliability of plunge milling. This paper proposes an optimization method to eliminate SIRD in five-axis plunge milling. Initially, a five-axis plunge milling experiment and an analysis of the spatial position relationship between the plunge tools and the workpiece revealed that the cause of SIRD is unreasonable tool path planning. Subsequently, using the cutter position and cutter axis vector as variables, an SIRD discrimination model was developed for adjacent cutter positions and extended to multiple cutter positions. Optimizing the plunge milling tool path is considered a multivariate optimization problem that involves determining the cutter point and cutter axis vector. The SIRD discrimination model was used as a constraint function to aid in solving for the variables. The simulation and experimental results indicate that with the remaining volume of material as the optimization target, the optimized plunge milling tool path results in a residual material volume that is less than 60% of the gradually decreasing plunge depth. This optimization decreases the subsequent semi-finishing time of the workpiece and enhances machining efficiency. Additionally, it does not rely on operator experience and facilitates efficient automated optimization of the tool path to exclude SIRD.
1. Introduction
A cavity typically refers to a pit structure enclosed by either a closed or partially closed boundary and is a common feature in machining processes. The primary objective of machining is to remove material to create various cavity structures. The cavity machining process generally involves three key factors: (1) machining accuracy [1–4], (2) machining performance [5–8], and (3) machining efficiency. Machining efficiency directly determines the economic benefits of part processing. According to statistics in the automotive industry, which includes the production of lamps, interior parts, and other large plastic molds, roughing of various cavity features accounts for more than 50% of the total processing time [9]. Notably, during the processing of large centrifugal compressor impellers, roughing time can exceed 70% [10, 11]. Therefore, finding ways to reduce roughing time is an important research direction aimed at improving processing efficiency.
Currently, layered milling is the predominant approach used for cavity processing. Layered milling is currently the primary approach for cavity processing [12, 13]. Owing to the typical material-removal pattern in cavity processing, the primary force direction of layered milling aligns with the weakest rigidity in the radial direction. Consequently, the efficiency of CNC machining of cavity parts is typically low. Moreover, the larger the size of the cavity parts, the more pronounced this issue becomes, further reducing processing efficiency. The plunge milling method, also known as Z-axis milling, involves feeding the cutter along the spindle direction and using the bottom cutting edge for combined drilling and milling. This method has several advantages, including a small radial milling force, good cutting stability, and the ability to use large-aspect-ratio cutters, making it well suited for the rough machining of deep cavities and deep groove parts [14–16].
Plunge milling tool path planning is a crucial aspect of plunge milling that has garnered considerable interest. Presently, the tool path planning module for three-axis plunge milling has become the standard configuration in major CAM software [17–20]. However, the tool path planning technology for five-axis plunge milling remains in the research and development stage. Only software such as NREC and Hypermill have released beta versions of five-axis plunge milling modules. In terms of tool path planning, Shan et al. [21] proposed a tool path planning algorithm for five- and four-axis plunge milling of blisk channels in aeroengine open-blisk machining. However, this method has...
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Xueqin Wang, Zhaocheng Wei, Dong Wang, Debao Zhang, Minjie Wang (2025). An Optimization Method for Five-axis Plunge Milling Tool Path Considering SIRD. Chinese Journal of Mechanical Engineering. https://doi.org/10.1186/s10033-025-01241-7
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Frequently Asked Questions
What is SIRD in plunge milling?
SIRD stands for Sudden Increase in Radial Depth, a phenomenon in plunge milling characterized by a sharp increase in cutting force at the end of the axial feed, often accompanied by harsh machine vibration sounds, which can negatively impact machining reliability.
What causes SIRD in five-axis plunge milling?
The study reveals that SIRD is caused by unreasonable tool path planning, specifically the spatial position relationship between the plunge tool and the workpiece.
How does the proposed optimization method work?
The method develops an SIRD discrimination model using cutter position and cutter axis vector as variables, and treats tool path optimization as a multivariate optimization problem with the SIRD model as a constraint function.
What are the benefits of the optimized tool path?
The optimized tool path reduces residual material volume to less than 60% of the gradually decreasing plunge depth, decreases subsequent semi-finishing time, enhances machining efficiency, and does not rely on operator experience.
Is the method applicable to automated optimization?
Yes, the method facilitates efficient automated optimization of the tool path to exclude SIRD, making it suitable for integration into CAM systems.
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