刀具偏心跳动下侧铣硬脆材料的瞬时铣削力模型

以侧铣可加工微晶陶瓷为对象,建立了瞬时整体铣削力模型,研究了刀具偏心跳动状态下立铣刀侧刃铣削瞬时铣削力。通过铣削刀具与工件的次摆线运动,获得了其瞬时切削厚度、瞬时切削面积。通过线性搜索法确定了刀具偏心量和偏心角的最优解,利用一维搜索算法进行了瞬时铣削力作用点的精确求解,并以刀具偏心跳动状态下的瞬时转角予以表达。以Martellotti模型为基础,建立了新的瞬时铣削力模型。以最小二乘法进行了瞬时铣削力模型系数辨识。并从铣削力作用点（瞬时转角）视角,研究了瞬时铣削力的变化特性。铣削实验验证结果表明,铣削力模型预测值与实验值吻合程度较高,平均相对误差不超过8%,该瞬时铣削力模型具有较高的预测精度。     

基于运动学的高速高精密铣削力建模：综合模型与试验

高速高精密铣削加工中铣削力是最重要的过程参量之一,铣削力信息的准确反馈对保证加工过程中的稳定性具有十分重要的意义。然而,影响铣削力大小的因素有很多种,目前缺乏一种考虑多种因素下的综合铣削力模型。因此,着重研究并综合考虑了刀具磨损、刀具跳动、刀具弹性变形对瞬时切削厚度的影响,同时分析了弹性变形对刀具切入与切出角的影响规律,改进了刀具瞬时切削厚度模型。基于运动学分析,将切削刃位置与预加工工件形态相互统一,建立了综合铣削力模型。为验证所提出综合模型的精确性和通用性,进行铣削实验,实验结果表明,铣削力预测值与实验值吻合较好,铣削力误差值小于1%,并通过分析刀具磨损与铣削力之间的相互变化关系,得出进给方向上的铣削力与Z向的铣削力系数对刀具磨损的影响最大。因此,切向力分量以及Z向的铣削力系数的变化特征可以较好的表征刀具磨损状况,从而提高铣削加工精度和效率。     

球头铣刀铣削力仿真技术研究

建立了适合任意进给方向的球头铣刀铣削力模型,并将铣削力仿真与几何仿真有机地结合起来,提出了快速准确地提取参与切削的切削微元的方法,并通过切削实验验证了铣削力模型。     

考虑刀具偏心的微铣削加工表面粗糙度预测模型研究

基于微铣削刀具轨迹建立了考虑刀具偏心、最小切削厚度的塑性材料微铣削底面粗糙度的预测模型,预测结果表明粗糙度表面形貌呈锯齿状,刀具偏心会影响表面粗糙度的形貌周期和高度,并进行微铣削加工实验,对粗糙度预测模型进行了验证。采用回归统计方法,建立了脆性材料微铣削加工表面粗糙度预测模型,对加工表面形貌进行观察,利用响应曲面法得到了各铣削用量对表面粗糙度的影响规律。     

SiC_p/Al复合材料高速铣削切削力模型建立

使用聚晶金刚石(PCD)刀具并采用正交试验设计法,对含不同体分比的碳化硅颗粒增强铝基复合材料(SiCp/2009Al)进行高速铣削试验。在测量切削力和切屑厚度的基础上,建立了剪切角、剪切应力和摩擦角的预测模型,并结合金属切削基本理论公式建立了切削力的预测模型。该模型包含铣削速度、每齿进给量、径向切宽、增强颗粒体分比等重要参数,模型对进给方向最大铣削力预测值的平均误差为5.9%,对铣刀径向切深方向最大铣削力预测值的平均误差为9.2%,皆高于普通经验公式的预测精度,从而可对SiCp/2009Al复合材料高速铣削时的铣削力进行有效预测。     

基于真实刀位轨迹的铣削厚度建模

瞬时未变形切削厚度是决定铣削加工切削力预测精度的一个重要参数.现有铣削力预测方法中,通常采用圆形轨迹逼近铣刀刀齿的运动轨迹并进行未变形切削厚度的计算.铣刀刀齿的实际运动轨迹为摆线轨迹,采用圆形轨迹近似必然造成在计算未变形切削厚度时存在误差.为获得更精确的铣削力预测结果,本文提出了一种基于刀齿真实轨迹的未变形切削厚度计算方法.通过计算铣刀刀齿的真实摆线运动轨迹,推导出未变形切削厚度计算的超越方程.通过对该超越方程的数值求解,得到了准确的未变形切削厚度.最后,通过算例分析及对比验证了所提方法的有效性.     

TC4的铣削加工中铣削力和刀具磨损研究

通过TC4铣削加工时的铣削力试验,研究了干切削时和有氮气介质铣削时影响铣削力大小的几个因素,为提高金属去除率优化了切削参数。同时通过刀具磨损试验,对上述两种铣削方式,比较了在不同的切削速度下铣削时铣刀后刀面的磨损,证实了以氮气为切削介质能够大大地改善刀具的磨损状况和提高刀具的寿命。     

钛合金薄壁件铣削过程有限元仿真分析

钛合金薄壁件铣削过程中,刀具角度对铣削过程中的工件变形、铣削力、铣削振动等影响显著。为减轻刀具磨损延长刀具寿命,通过ABAQUS软件建立钛合金Ti6Al4V薄壁件铣削过程仿真模型,以铣削力和铣削温度为评价指标,采用单因素和正交法分析了刀具前角、后角及螺旋角对铣削力和铣削温度的影响规律,并对铣削力仿真结果进行试验验证。仿真结果表明:前角增大,铣削力减小,铣削温度呈波动趋势变化;后角增大,铣削力减小,铣削温度先减小后增大;螺旋角增大,最大轴向力增大,最大切向力缓慢减小,最大径向力基本不变,铣削温度先减小后增大。通过正交试验和极差分析,明确不同因素对指标影响程度的主次顺序和因素的最优水平组合。     

高速铣削淬硬钢刀具刃口对表面粗糙度影响试验研究

采用立式铣刀及球头铣刀进行高速铣削Cr12MoV淬硬模具钢表面测试试验研究,利用KEYENCE超景深显微镜获得刃口半径,利用正交试验设计方法,分析刀具刃口半径及切削参数对高速铣削淬硬钢表面粗糙度的影响规律。结果表明:在铣削平面过程中,刀具刃口半径对工件表面粗糙度有显著性影响;而在铣削曲面时,刀具刃口半径对表面粗糙度的影响并不显著。     

通过铣削力或铣削扭矩监测铣刀破损的研究

为了通过铣削力或铣削扭矩波形的不均匀程度来识别铣刀是否发生破损,提出了两类识别方法。一类是计算齿周期峰值变化率;一类是计算相对最大切削厚度的偏心率。两类算法均简单、可靠,可用于各种铣削加工过程的铣刀破损监测。     

沟槽织构球头铣刀刀具结构强度仿真研究

为研究横向沟槽微织构的制备对刀具应力和应变的影响,采用有限元仿真方法,针对横向沟槽微织构形式,进行了刀具结构强度的仿真。同时,研究了不同横向沟槽微织构参数对球头铣刀结构强度的影响规律。     

虚拟制造系统中球头铣刀磨损预测

基于球头铣刀铣削方式及铣削参数的特点,应用微分理论基本方法提出了一种虚拟制造系统中球头铣刀磨损预测的数学模型,为提高虚拟制造系统的真实感和实时性奠定了基础.     

多曲面岛屿五轴螺旋刀位轨迹规划

针对复杂拓扑关系的多曲面岛屿加工,以叶片阻尼台为研究对象,提出基于清根刀心轨迹的五轴球头刀螺旋刀位轨迹生成算法。首先建立局部坐标系,定义并确定中轴线,然后按层逐点创建投影射线,利用实体求交构造初始刀心螺旋轨迹;通过变步长迭代算法修正,使得刀心点距实体最短距离在加工精度范围内等于刀具半径。最后根据实体结构控制刀轴矢量,规划出无干涉的螺旋刀位轨迹。算例表明,本文算法统一了阻尼台加工与清根加工,避免了复杂偏置曲面片的构造,保证在加工过程中没有冗余进退刀的同时刀具不会过切叶身曲面,实现了阻尼台多曲面岛屿五轴球头刀高效精密加工。     

Time-domain modeling of a cutter exiting a workpiece in the slot milling process

In a milling operation, there must be processes of a cutter entering and exiting the work-piece boundary. The cutter exit is usually in the feed direction and the dynamic response is different from that in the normal cutting process. This paper presents a new time-domain modeling of mechanics and dynamics of the cutter exit process for the slot milling process. The cutter is assumed to exit the workpiece for the first time with one tooth right in the feed direction. The dynamic chip thickness is summed up along the feed direction and compared with the remaining workpiece length in the feed direction to judge whether the cutter is ready to exit the workpiece or not. The developed model is then used for analyzing the cutting force and machining vibration in the cutter exit process. The developed mathematical model is experimentally validated by comparing the simulated forces and vibrations against the measured data collected from real slotting milling tests. The study shows that stable cutting parameters cannot guarantee stable cutting in a cutter exit process and further study can be performed to control the vibration amplitude in this specific process.     

Ti—1023钛合金的立铣问题

本文对Ti-1023钛合金的立铣进行了研究。测量了顺铣逆铣时的切削力,分析了铣削力、立铣刀挠度对精度的影响,推荐了Ti-1023钛合金立铣(铣周边、铣槽)的切削参数。     

Four-axis trochoidal toolpath planning for rough milling of aero-engine blisks

The Blade Integrated Disk (Blisk) is one of the key components in the aero-engine, it is generally manufactured by the multi-axis milling and almost 90% raw materials are removed. To avoid the full immersion of a cutter in the rough machining of a blisk channel, the trochoidal milling is a promising strategy since it can keep a small immersion angle in the rough milling process while maintaining the high machining efficiency. However, while toolpaths are being planned for the trochoidal milling process, the conventional methods are mainly for the planar machining area with fixed tool orientations, which cannot be used for complex channels where the multi-axis machining should be employed. To this end, this paper presents a four-axis trochoidal toolpath planning method with a ball-end cutter, and thus the blisk channel can be machined efficiently. For this to happen, the trochoidal paths are planned in the parametric domain and then mapped into the physical domain, with tool orientations controlled by the quaternion interpolation method to have smooth tool movement along the toolpaths. Both geometric simulation and physical milling experiments of the proposed method have convincingly demonstrated the validation of the proposed method.     

Mechanistic identification of cutting force coefficients in bull-nose milling process

An improved method to determine cutting force coefficients for bull-nose cutters is proposed based on the semi-mechanistic cutting force model. Due to variations of cutting speed along the tool axis in bull-nose milling, they affect coefficients significantly and may bring remarkable discrepancies in the prediction of cutting forces. Firstly, the bull-nose cutter is regarded as a finite number of axial discs piled up along the tool axis, and the rigid cutting force model is exerted. Then through discretization along cutting edges, the cutting force related to each element is recalculated, which equals to differential force value between the current and previous elements. In addition, coefficient identification adopts the cubic polynomial fitting method with the slice elevation as its horizontal axis. By calculating relations of cutting speed and cutting depth, the influences of speed variations on cutting force can be derived. Thereby, several tests are conducted to calibrate the coefficients using the improved method, which are applied to later force predictions. Eventually, experimental evaluations are discussed to verify the effectiveness. Compared to the conventional method, the results are more accurate and show satisfactory consistency with the simulations. For further applications, the method is instructive to predict the cutting forces in bull-nose milling with lead or tilt angles and can be extended to the selection of cutting parameters.     

铣削过程中误差预测与补偿技术研究进展

 研究铣削过程的机理,对于实现加工过程的精密化与高效化至关重要。介绍了国内外铣削仿真模拟的研究进展,阐述了数值计算方法以及有限元技术在铣削误差控制中的具体应用。对切削力建模方法、表面误差预测方法、材料去除建模方法以及误差补偿等关键技术进行了重点介绍,并对各关键技术所包括的核心思想、算法及仿真流程进行了详细讨论。最后对铣削过程误差控制技术的发展方向做出了展望。     

通用后置处理系统

对后置处理软件的通用化,模块化、标准化做了比较全面的、系统的分析和研究,并在此基础上提出了标准刀位文件和数据驱动式用户接口,为后置处理程序的商品化、工程化奠定了基础。