高缠绕叶轮流道4+1轴高效分段开槽方法

高缠绕叶轮流道的高效粗加工是提高整个叶轮加工效率和缩短生产周期的关键。针对高缠绕叶轮流道的粗加工,提出了一种4+1轴高效分段开槽方法。首先,给出了分段开槽加工方法的基本概念,并分析了高缠绕叶轮流道加工特点;然后,结合机床结构特征,给出了五轴机床在主轴摆角固定为常值时切削点处单点最大刀具尺寸的计算方法;基于各切削点加工特征参数的分析,采用聚类算法进行了叶轮流道加工分段区域的划分;最后,确定了各分段区域的可加工刀具尺寸和4+1形式的刀轴矢量。算例分析表明,提出的4+1轴分段开槽方法得到的开槽轨迹旋转轴变化均匀,材料去除量较传统开槽方法增加了32.5%,改善了切削过程稳定性,提高了叶轮的粗加工效率。

High-efficiency section-by-section slotting method for 4+1-axis NC machining of high-wrap impeller channel

High-efficiency rough machining method for the high-wrap impeller channel is the key path to enhance the whole impeller machining efficiency and shorten the production cycle. Aiming at the rough machining of high-wrap impeller channel, a high-efficiency slotting method for 4+1-axis section-by-section NC machining of high-wrap impeller channel is proposed in this paper. Firstly, the basic concept of the method is discussed from the machining principle and the five-axis machining features of the high-wrap impeller are analyzed. Secondly, the largest available tool of each cutting point is determined according to the structural features of the machine. The division of the high-wrap impeller channel machining region is made based on the analysis of the processing characteristics of each cutting point using the clustering algorithm. Finally, the largest available tool and the tool orientation in form of 4+1-axis of each subsection are calculated. Simulation results demonstrate that the proposed method obtains linearly changed rotational coordinates along the slotting path, material removal volume increased by 32.5% than the traditional slotting method, the impeller slotting machining stability and efficiency are obviously improved.