基于系统运动学及无碰撞约束的五轴增减材复合制造工艺规划方法

doi:10.7527/S1000-6893.2025.32288

Abstract

Abstract:

Additive and Subtractive Hybrid Manufacturing （ASHM） demonstrates significant advantages in fabricating complex aerospace components. However， its coupled process characteristics substantially increase the complexity of process planning. Furthermore， insufficient surface smoothness of the model can lead to rapid acceleration and deceleration during CNC machining， adversely impacting surface quality. To address these challenges， this study proposes a kinematic optimization and collision-free rapid process planning method for ASHM. First， under shape error tolerance constraints， a mathematical optimization model was established using spline control points as variables， with jerk suppression as the optimization objective. Surface smoothing pre-processing tailored for machining was achieved by optimizing the cross-sectional curves and applying a skinning operation. Next， the smoothed part was segmented into sub-entities based on geometric and topological features. Utilizing volumetric tetrahedral meshing， a geodesic distance field was constructed for each sub-entity， enabling parametric layering and providing essential input for ASHM process planning. Finally， fully considering the geometric changes in the part before and after each ASHM step， evaluation models for machinability and printability with rapid assessment algorithms were established. These algorithms evaluate collision and interference during both additive and subtractive manufacturing phases. Using this evaluation as constraints， an ASHM process planning model based on ‘up-to-down’ strategy was proposed. Both simulations and machining experiments were conducted using a blade model. By comparing with traditional uniform thickness process planning methods， the effectiveness of the method proposed in this paper has been verified， providing theoretical basis and technical support for multi-axis additive-subtractive composite manufacturing of complex structural parts.

Key words: additive and subtractive hybrid manufacturing, model parameterization, smoothing optimization, collision detection, process planning

CLC Number:

V262

Xishuang JING, Xinhao LI, Fubao XIE, Ben MU, Chengyang ZHANG. Process planning method for five-axis additive and subtractive hybrid manufacturing based on system kinematics and collision-free constraints[J]. Acta Aeronautica et Astronautica Sinica, 2026, 47(4): 432288.

Figures/Tables 17

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轴	加速度标准差				加加速度标准差
轴	单位	优化前	优化后	变化幅度	单位	优化前	优化后	变化幅度
X	mm·s^-2	43.26	32.36	-25.20%	10³ mm·s^-3	24.15	19.32	-20.02%
Y	mm·s^-2	23.72	18.07	-23.83%	10³ mm·s^-3	16.34	10.78	-33.99%
Z	mm·s^-2	51.69	38.57	-25.38%	10³ mm·s^-3	38.83	31.55	-18.74%
C	（°）·s^-2	39.99	28.03	-29.90%	10³（°）·s^-3	27.12	19.41	-28.44%

轴	加速度绝对值均值				加加速度绝对值均值
轴	单位	优化前	优化后	变化幅度	单位	优化前	优化后	变化幅度
X	mm·s^-2	30.57	24.11	-21.13%	10³ mm·s^-3	19.47	15.70	-19.39%
Y	mm·s^-2	18.85	14.60	-22.53%	10³ mm·s^-3	13.25	8.76	-33.87%
Z	mm·s^-2	40.90	30.77	-24.78%	10³ mm·s^-3	30.86	25.24	-18.20%
C	（°）·s^-2	28.58	20.40	-28.60%	10³（°）·s^-3	21.33	15.03	-29.54%

偏差	零件背面			零件正面
偏差	优化前	优化后	变化幅度	优化前	优化后	变化幅度
偏差平均值/mm	0.017 7	0.014 1	-20.33%	0.017 2	0.015 15	-11.91%
偏差标准差/mm	0.023 5	0.021	-10.63%	0.024 5	0.021 9	-10.61%

Process planning method for five-axis additive and subtractive hybrid manufacturing based on system kinematics and collision-free constraints

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