A GPU-based tool parameters optimization and tool orientation control method for four-axis milling with ball-end cutter

Aiming at tool parameters selection and tool axis control in the four-axis machining process with a ball-end cutter, a GPU-based method is proposed in this paper. Firstly, based on the characteristics of the tool movement in four-axis machining, the feasible domain of discrete space for the tool is defined. Through the analysis of factors affecting the selection of tool parameters, a tool parameter optimization model is established. Secondly, an Automatically Programmed Tools (APT) tool model is used as the tool model. Basically, a simplified model of a ball-end cutter and tool holders is established, and the calculation methods for the critical tool diameters and the critical tool lengths in feasible domains are determined. After that, through the analysis and application of GPU parallel computing technology, a discrete feasible domain calculation, as well as the rapid solution of the critical tool parameters, is realized. To validate the developed method, tool diameters and orientations are optimized for machining of an open blisk. The validation demonstrates that this method can be used to select the optimal tool parameters and to obtain the overall smooth tool orientations.