Tool orientation optimization and location determination for four-axis plunge milling of open blisks

Plunge milling has been widely adopted in the manufacturing industry to rough machine open blisks, and its objective is to remove stock material with high efficiency and machining stability. A current technique challenge is to calculate the tool orientation and locations (called plunger paths) in four-axis rough plunging of open blisks, so that the residual raw material left on the blades after roughing is close to the specified value. To address this challenge, a novel approach is proposed to optimize tool orientation and determine tool locations for four-axis plunge milling of open blisks. First, tool locations are determined with two principles without interfering the blades and hub. Second, tool orientation is optimized according to a new evaluation criterion. Then, considering the impact of previous tool paths, an in-process model of a blisk is used to calculate residual material. Finally, an experiment is conducted to verify this new approach. This approach can promote four-axis plunge milling in the open blisk manufacturing.