Hausdorff Distance-based Tool Position Planning Method for Plunge Milling of 3D Impeller Channels in Shroud-enabled Blade Milling

In the context of plunge milling for rough-machined three-dimensional (3D) impeller channels using the shroud-enabled blade milling method, substantial non-uniform allowances often persist on the inner surface of the shroud. To address this issue, in the present study, a tool pose and position optimisation method based on the Hausdorff distance was proposed. A mathematical model was developed to optimise the initial pose and position of a flat-bottomed tool by minimising the unidirectional Hausdorff distance from its bottom plane to the inner surface of the shroud. This optimisation ensures that the allowance on the inner surface of the shroud after plunge milling is both minimal and uniformly distributed. Numerical simulations demonstrate that the proposed method reduced the mean absolute error by 57.79% and significantly enhanced the uniformity of the error distribution, thereby verifying its effectiveness in improving machining accuracy.