复杂曲面加工刀轴矢量优化研究

本文对某复杂曲面的多轴数控加工刀轨进行了研究,针对该曲面的特征,采用可变轮廓铣策略;优化刀轴矢量,实现在曲面切削时,刀具的切削点到刀轴的投影距离最大,从而实现最大切削速度,提高表面质量。本文构建了切削过程的刀轴矢量变化模型,最终完成刀轴矢量旋转角的优化。经验证采用该策略及模型能获得较高的表面质量和精度,达到设计和精度要求。     

复杂曲面五坐标加工中双线驱动刀轨规划(英文)

针对目前利用包含环面刀具等多种刀具加工复杂曲面时普遍存在的不能实现一阶连续问题,本文提出了一种复杂曲面五坐标加工中双线驱动刀轨规划算法。该方法首先利用多点法来优化每一个刀位,从而获得整行刀轨的最大加工带宽,于是可以在工件曲面上确定两条驱动线。然后,在保证刀轨光顺的前提下,使刀具沿着两条驱动线滑动,且在每个刀触点处都重新定位刀具。最后,通过仿真和加工试验来验证该方法的有效性,并利用三坐标测量机对加工型面进行了测量,结果表明该方法能有效地消除相邻刀轨衔接处的尖锐残高、保证刀轨的光顺性和提高曲面的加工质量。     

透平机叶轮叶片五轴数控粗加工优化方法的研究

为提高透平机叶轮叶片的加工质量和效率,在粗加工阶段,提出采用侧铣方法代替传统五轴数控加工中点铣,实现高效加工。基于多片直纹面包络叶片型面,提出一套复杂曲面蜕变直纹面方法,并给出相应算法,实现侧铣加工。以喷推叶轮为例,采用UG-NX进行建模与数控编程,用VERICUT刀轨仿真,通过加工路径的比较,对加工效率进行量化分析。结果表明,采用分段侧铣方法,生成的刀轨刀轴矢量变化均匀,刀具和零件未发生干涉,加工效率和加工质量明显得到提高。     

开式整体叶盘四坐标插铣开槽粗加工刀位轨迹规划

提出在开式整体叶盘的粗加工阶段,采用插铣加工代替传统的五轴数控加工点铣和侧铣,实现高效加工.提出将自由曲面蜕变为直纹面,将复杂自由曲面粗加工问题转化为简单的直纹面粗加工问题.这种方法的加工效率比传统加工方法提高约60%以上.     

一种叶片截面线光顺及等距面生成方法

采用等距面生成球头刀加工刀具轨迹是曲面加工中一种常用的方法。但是,在对叶身曲面进行等距偏置时,经常出现无法偏置的问题。针对该问题,分析了曲面偏置自相交原因,并根据叶片类零件叶身曲面的特点,提出了一种叶身截面线光顺及等距面生成方法。该方法首先采用Kjellander方法将原始截面线进行自动光顺,然后根据光顺后的原始截面线和数据采样法构造偏置截面线,最后通过截面线放样法构造叶身曲面等距面。实例表明,采用Kjellander方法可以实现叶片曲面的自动光顺和叶片曲面等距面的构造。     

复杂曲面零件五轴加工刀轴整体优化方法

 针对复杂曲面零件五轴加工中刀轴矢量变化剧烈、严重影响工件表面加工质量的问题,提出一种基于临界约束的五轴刀轴矢量整体优化方法。首先,构造了给定切触点处所有可行摆刀平面,并在摆刀平面内根据临界约束计算出临界刀轴矢量,在获得临界刀轴矢量的基础上,对其进行平面映射,建立了刀轴摆动的初始可行域;其次,通过对初始可行域进行均匀离散,根据离散点之间相对位置关系构造邻接矩阵,并结合最短路径搜索算法获得了初始参考刀轴,从而构造了新的刀轴摆动可行域;最后,建立当前切削行内无干涉且相邻刀轴变化最小的刀轴矢量优化模型,实现自由曲面五轴加工无干涉刀轴矢量的光滑控制。两种自由曲面叶轮的加工算例分析表明,采用本文方法获得的刀轴矢量可以明显改善机床的运动性能,避免了刀具干涉的产生,可提高复杂曲面零件的加工质量与效率。     

多轴刀具轨迹的偏置计算方法

本文就图象编程刀位计算的几个重要方面,提出了较完整的处理方法:刀位计算程序控制结构及用户友好的控制参数通讯区接口;多轴刀具轨迹偏置计算,其中详细介绍了端铣、侧铣的刀位计算过程和干涉碰撞的检查与修正;加工边界和尖角过渡处理中,引入了尖角邻接关系。上述方法在复杂曲面零件整体加工的图象编程中,具有重要的实用价值。     

整体叶轮侧铣数控加工刀位轨迹生成新方法

为提高整体叶轮的加工质量和效率,提出了分段侧铣的方法,在每一段曲面上,基于斜等距曲面的原理,推导出叶片分段侧铣加工时刀位轨迹的生成和计算;并用计算仿真和刀心轨迹图对刀位进行了验证。结果表明,采用分段侧铣的方法,生成的刀位轨迹刀轴矢量变化均匀,刀轴未发生干涉,且加工效率和加工质量明显得到提高。     

中凹盘铣刀数控端铣弧齿锥齿轮

为了解决当前数控加工中通用刀具加工弧齿锥齿轮存在的加工效率低、易切削颤振等问题,提出了中凹盘铣刀数控端铣弧齿锥齿轮的方法.基于对弧齿锥齿轮齿面几何结构的研究,通过选择大直径、刀底内凹的盘形铣刀,主动改变刀具姿态角的设置顺序,并分离了前倾角和侧倾角的功能,可以实现弧齿锥齿轮的齿底无干涉和大切削带宽加工.先以切触点位置确定侧倾角避免过切齿槽底面,再以平底刀加工自由曲面的思想分别确定两侧齿面的前倾角,保证大的切削带宽和高加工效率.结果表明:以一个弧齿锥齿轮大轮为例,中凹盘铣刀端铣轮两侧齿面分别以7次、6次切削完成加工,最大加工误差分别为0.039 4mm和0.041 8mm.采用该方法加工弧齿锥齿轮,具有刀具耐用度高,切削带宽大,走刀次数少和加工精度高等优点.     

基于经线划分的非圆截面环形刀具刀位优化算法

目前环形刀具的刀位算法均未考虑圆刀片安装时存在的俯仰角和偏转角,因而在理论上存在较大的编程误差。针对实际使用刀具为非圆截面环形刀具的情况,通过对环形刀具的截面曲线进行分析,提出了一种基于经线划分的非圆截面环形刀具刀位优化算法。首先利用经线法求解出刀具表面和工件曲面之间的误差分布,然后根据此误差分布来调整刀具位置和姿态,使刀具表面与设计曲面在不发生干涉的情况下实现密切接触,从而得到刀具在指定定位点处的最优刀位。仿真结果表明,传统的五坐标刀位算法会产生较大的加工误差,而本文提出的算法消除了圆刀片安装时存在的俯仰角和偏转角所引起的加工误差,可有效提高复杂曲面的加工精度并获得满足给定编程公差的优化刀位。     

Positioning method of a cylindrical cutter for ruled surface machining based on minimizing one-sided Hausdorff distance

Motivated by the definition of the machining errors induced by tool path planning methods, a mapping curve of the tool axis of a cylindrical cutter is constructed on the tool surface.The mapping curve is a typical one that can be used to express the closeness between the tool surface and the surface to be machined. A novel tool path planning method is proposed for flank or plunge milling ruled surfaces based on the minimization of the one-sided Hausdorff distance(HD) from the mapping curve to the surface to be machined. It is a nonlinear optimization problem in best uniform approximation(BUA) or Chebyshev sense. A mathematical programming model for computing the minimum one-sided HD is proposed. The linearization method of the programming model is provided and the final optimal solutions are obtained by simplex method. The effectiveness of the proposed BUA method is verified by two numerical examples and compared with the least squares(LS) and double point offset(DPO) methods. The variation in tool orientation induced by the optimization of the tool positions is also evaluated.     

基于中轴变换的型腔高速铣削刀具轨迹生成方法

框、梁、壁板、蒙皮等飞机关键零部件中包含大量型腔特征,其加工效率直接影响零件的整体加工效率。高速铣削机床的发展为此类零件的高效加工奠定了很好的硬件基础,也给型腔铣削刀具轨迹生成带来了新的问题。例如蒙皮镜像铣由于其特殊的设计,对刀具轨迹提出平滑无抬刀、步距变化严格控制在一定范围内等更严苛的要求,从而保证蒙皮高质量加工。结构件高速加工中为了保持刀具的高进给和高转速,也要求刀具轨迹平滑且步距平稳变化。然而现有的型腔铣削刀轨生成方法大多基于局部优化解决加工残余和刀轨不平滑问题,难以生成同时满足多工艺约束尤其是步距约束的刀具轨迹,无法完全发挥高速机床的性能。针对此问题,本文提出基于中轴变换的型腔高速铣削刀具轨迹生成及优化方法。该方法首先基于中轴变换提取型腔骨架线,并进一步修正从而生成刀轨偏置基准和初始刀轨。其次利用图像变形算法对初始刀轨进行迭代变形优化,使最终优化刀轨与目标型腔区域吻合,且满足高速加工的工艺约束条件。该方法在离散的图像域内从整体角度优化刀具轨迹,不仅保证轨迹平滑无抬刀,还能保证步距在容许范围内平稳变化。实验证明本文提出的方法在保证轨迹平滑和步距平稳变化等方面的有效性,能够满足高性能加工的要求。     

Five-axis flank milling tool path generation with curvature continuity and smooth cutting force for pockets

In order to ensure machining stability, curvature continuity and smooth cutting force are very important so as to meet the constraints of both cutting force and kinematics of machine tools. For five-axis flank milling, it is difficult to meet both of the constraints because tool path points and tool axis vectors interact with each other. In this paper, multiple relationships between tool path points and tool axis vectors with cutting force and kinematics of machine tools are established, and the strategies of corner-looping milling and clothoidal spirals are combined so as to find feasible solutions under both of the constraints. Tool path parameters are iterated by considering the maximum cutting force and the feasible range of the tool axis vector, and eventually a curvature continuity five-axis flank milling tool path with smooth cutting force is generated. Machining experimental results show that the conditions of cutting force are satisfied, vibration during the process of machining is reduced, and the machining quality of the surface is improved.     

Optimal interface surface determination for multi-axis freeform surface machining with both roughing and finishing

In the current practice of multi-axis machining of freeform surfaces, the interface surface between the roughing and finishing process is simply an offset surface of the nominal surface. While there have already been attempts at minimizing the machining time by considering the kinematic capacities of the machine tool and/or the physical constraints such as the cutting force, they all target independently at either the finishing or the roughing process alone and are based on the simple premise of an offset interface surface. Conceivably, since the total machining time should count that of both roughing and finishing process and both of them crucially depend on the interface surface, it is natural to ask if, under the same kinematic capacities and the same physical constraints, there is a nontrivial interface surface whose corresponding total machining time will be the minimum among all the possible (infinite) choices of interface surfaces, and this is the motivation behind the work of this paper. Specifically, with respect to the specific type of iso-planar milling for both roughing and finishing, we present a practical algorithm for determining such an optimal interface surface for an arbitrary freeform surface. While the algorithm is proposed for iso-planar milling, it can be easily adapted to other types of milling strategy such as contour milling. Both computer simulation and physical cutting experiments of the proposed method have convincingly demonstrated its advantages over the traditional simple offset method.     

超高强度钢立铣工件温度分析及对加工表面质量的影响

以航空难加工材料300M钢为研究对象,基于立铣加工中的工件温度判断在铣削加工中是否出现了金相组织转变,进而分析不同工况下影响加工表面质量的因素。首先,将移动热源法应用于铣削加工中,计算考虑后刀面磨损的立铣加工工件温度,实验表明,计算值与实验值相比误差在10%以内。然后,分析了工件温度在时间上与空间上的分布,以及不同刀具磨损和加工参数条件下工件表面的温升规律,据此预测加工表面是否出现了组织转变,并结合金相组织观察进一步确认。最后,依据加工表面质量物理层面残余应力和显微硬度的检测数据,初步探讨了各因素对表面质量的影响。结果表明,在研究的加工参数范围内,并未达到金相组织转变温度,表面质量主要受铣削热力作用下的剪切面塑性凸出效应、后刀面挤光效应和热效应的影响。     

Dual Drive Curve Tool Path Planning Method for 5-axis NC Machining of Sculptured Surfaces

The problem of finished surface being not first-order continuous commonly exists in machining sculptured surfaces with a torus cutter and some other types of cutters. To solve this problem, a dual drive curve tool path planning method is proposed in this article. First, the maximum machining strip width of a whole tool path can be obtained through optimizing each tool position with multi-point machining (MPM) method. Second, two drive curves are then determined according to the obtained maximum machining strip width. Finally, the tool is positioned once more along the dual drive curve under the condition of tool path smoothness. A computer simulation and cutting experiments are carried out to testify the performance of the new method. The machined surface is measured with a coordinate measuring machine (CMM) to examine the machining quality. The results obtained show that this method can effectively eliminate sharp scallops between adjacent tool paths, keep tool paths smooth, and improve the surface machining quality as well as machining efficiency.     

镜像铣削加工奇异区域刀具路径优化

在大型薄壁件镜像铣削加工中,由奇异点引起的旋转轴运动不连续会影响加工质量,降低加工效率。针对此问题,分析了镜像铣削加工奇异点存在的原因,提出了一种奇异区域内的刀具路径优化方法。首先,针对镜像铣削系统的铣削头和支撑头分别建立了其旋转轴运动学变换模型,推导旋转轴微分运动关系,据此分析奇异点存在的原因及其对加工质量和效率的影响,定义了机床行程内的奇异区域范围。分析结果表明在镜像铣削系统行程范围内,仅铣削头存在奇异区域,而支撑头不存在奇异区域。然后,在镜像铣削加工刀路约束条件下,基于刀路光顺性指标建立了刀路优化模型。通过在加工曲面参数域内对跨越铣削头奇异区域的刀路进行调整,使得优化后的刀路更加光顺,以提高加工精度和表面质量,减少奇异区域附近的加工时间。最后,通过镜像铣削加工实验验证所提方法的有效性。     

自由曲面叶轮的四坐标数控加工研究

 针对自由曲面叶轮的四坐标加工，提出了一种刀轴矢量的确定方法。给定工作台倾斜角度和刀具后跟角，四坐标加工的刀轴矢量必然位于这两个角度确定的两个圆锥面上。通过对两个圆锥面求交并结合叶轮加工的实际特点，给出了自由曲面叶轮四坐标加工刀轴矢量的计算方法。根据得到的刀轴矢量，计算相应的侧偏角，从而可将五坐标加工的理论和方法直接应用于四坐标加工中。算例表明，该方法合理可行，能够有效提高四坐标加工效率、降低叶轮加工成本，并可推广至一般曲面的四坐标加工以及五轴四联动加工。     

Trajectory optimisation in electrical discharge machining of three-dimensional curved and twisted channels

Numerical control electrical discharge machining(NC EDM) is one of the most widely used machining technologies for manufacturing a closed blisk flow path, particularly for three-dimensional(3D) curved and twisted flow channels. In this process, tool electrode design and machining trajectory planning are the key factors affecting machining accessibility and efficiency. Herein, to reduce the difficulty in designing the electrode and its motion path in the closed curved and twisted channels, a heur...