Integrated optimization of tool orientation in five-axis freeform milling using particle swarm optimization algorithm
Journal
Journal of Mechanics
Journal Volume
42
Start Page
1
End Page
11
ISSN
17277191
Date Issued
2026
Author(s)
Abstract
Five-axis milling of free-form surfaces requires simultaneous optimization of toolpaths and continuously varying tool orientations. However, most commercial CAM workflows focus only on geometric simulation and neglect critical physical quantities such as cutting forces, leading to force spikes, tool deflection and surface inaccuracies. This study proposes an integrated optimization framework that combines automatic toolpath generation from STEP/B-Rep models with solid-model-based extraction of cutter–workpiece engagement (CWE). The CWE data are transformed into entry and exit immersion parameters and undeformed chip thickness to enable mechanistic cutting-force prediction. Tool orientations are then optimized using a curvature-aware parameterization method and a particle swarm optimization (PSO) algorithm. Numerical validation on representative free-form surfaces demonstrated that the proposed method reduced the maximum cutting force from 214 N to 170 N (a 20.6% reduction) compared with the original path. A secondary optimization stage incorporating polynomial-fitted force smoothing decreased force fluctuation amplitude by over 40%, resulting in both smoother tool-axis trajectories and improved machining stability. By integrating geometric modeling, physical simulation and metaheuristic optimization, the proposed PSO-based framework provides a quantitatively verified improvement in force-aware toolpath planning. The approach can be readily incorporated into existing CAD/CAM environments for efficient and reliable five-axis machining of complex free-form surfaces.
Subjects
boundary representation (B-Rep)
cutter-workpiece engagement (CWE)
cutting forces
five-axis milling
particle swarm optimization (PSO)
Publisher
Oxford University Press
Type
journal article