Integral Impeller Plunge Milling Path Layout to Cut Redundant Passes

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Solution Overview

Problem

Current plunge milling technologies for integral impellers lack efficient cutter path arrangements, leading to redundant paths and reduced processing efficiency, making it difficult to improve upon established high feed layer cutting methods.

Innovation Solution

A double-row slot plunge milling method that involves analyzing CAD models, determining optimal cutter diameters and paths, segmenting flow channels, and arranging cutter paths to minimize bumping and vibration, using CAM software for precise planning and execution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional high feed layer cutting processing is used, then processing efficiency reaches a certain level, but it is difficult to obtain further improvement

Engineering Contradiction:

Improveprocessing efficiencyVSAvoidcutting stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent transitions from layer-by-layer cutting parameters to plunge milling parameters, changing the fundamental cutting mode. By adjusting cutter diameter selection criteria, feed rate parameters, and depth of cut values, the process achieves both high efficiency and stability simultaneously

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces dynamic cutter path planning that adapts to varying flow channel geometries. The processing method dynamically adjusts cutting parameters based on local cross-sectional dimensions, enabling the system to maintain optimal performance across different workpiece regions

Inventive Principle:

Principle #15Dynamics

2Productivity

If plunge milling technology is introduced to improve processing efficiency, then efficiency can increase by 50% or more, but redundant cutter paths are generated

Engineering Contradiction:

Improveprocessing efficiencyVSAvoidredundant cutter paths

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent segments the flow channel processing into distinct zones based on cross-sectional width variations. By dividing the continuous flow channel into discrete processing segments, the method eliminates redundant cutter paths while maintaining efficient plunge milling operations in each segment

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent performs preliminary analysis of the flow channel geometry to pre-determine optimal cutter paths and segment boundaries. This preliminary planning action prevents generation of redundant paths during actual machining, saving time while maintaining high efficiency

Inventive Principle:

Principle #10Preliminary action

3Speed

If cutter diameter is increased to reduce number of passes, then processing speed improves, but cutter bumping occurs

Engineering Contradiction:

Improveprocessing speedVSAvoidcutter bumping

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The patent applies local quality by selecting different cutter diameters for different processing segments based on local cross-sectional dimensions. In wider sections, larger cutters are used for high-speed processing, while in narrower sections, smaller cutters are selected to prevent bumping, optimizing both speed and reliability locally

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The method incorporates feedback through continuous monitoring of cutter position and workpiece geometry during plunging. When approaching potential bumping conditions, the system automatically adjusts cutting parameters or retracts the cutter, preventing damage while maintaining high processing speed

Inventive Principle:

Principle #23Feedback

4Manufacturing precision

If complex cutter path arrangement is used to cover all areas, then processing completeness improves, but processing time increases

Engineering Contradiction:

Improveprocessing completenessVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent utilizes the axial dimension for plunge milling operations, allowing the cutter to remove material directly from the top surface downward. This dimensional approach enables complete coverage of flow channel areas with fewer paths compared to traditional lateral milling, reducing processing time while maintaining completeness

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS11007611B2Double-row slot plunge milling processing method for integral impellers

Publication Date: 2021.05.18 DALIAN UNIV OF TECH

AI summary

A double-row slot plunge milling processing method for integral impellers, which comprises planning a double-row plunge milling cutter path along two side blades of an impeller flow channel; a cutter arrangement sequence of the cutter path following the direction of an inlet and outlet of the flow channel; determining cutter diameter according to the width of a bottom portion of a cross-section of the flow channel and segmenting the flow channel, the width of a bottom portion of the cross-section of each segmented flow channel being greater than one times the cutter diameter and smaller than two times the cutter diameter. Compared with existing methods for layer cutting of high feed, the present invention can increase rough-processing efficiency of integral impellers by more than 50%, while facilitating the elimination of plunge milling cutter bumping, and effectively reducing redundant cutter paths; the implementation process being simple and facilitating CAM software integration.