微小整体叶轮五轴联动微细铣削加工试验研究

微小整体叶轮作为微型发动机的重要组成部分,其加工质量直接影响微型发动机的使用性能。针对微小整体式复杂叶轮流道狭窄、叶片扭曲大和长厚比大等特点,开展了微小复杂扭曲整体式叶轮五轴联动微细铣削加工方法研究。针对微小叶轮加工过程极易发生变形、过切和碰撞干涉等问题,对微小叶轮的加工过程进行工艺规划,建立了微小叶轮流道加工刀具选择的约束方程,计算出叶轮加工刀具的最大理论直径。通过CAM软件对叶轮进行切削仿真,验证了刀具选择和工艺规划的正确性。通过五轴联动微细铣削试验,得到了具有6个直径10mm的叶片、叶片最小厚度0.15mm、叶片最小相邻间距0.58mm的7075铝合金微小整体叶轮。     

Prediction of cutting forces in flank milling of parts with non-developable ruled surfaces

Predicting the cutting forces required for five-axis flank milling is a challenging task due to the difficulties involved in determining the Undeformed Chip Thickness(UCT) and CutterWorkpiece Engagement(CWE). To solve these problems, this paper presents a new mechanistic cutting force model based on the geometrical analysis of a flank milling process. In the model,the part feature and corresponding cutting location data are taken as input information. The UCT considering cutter runout is calculated according to the instantaneous feed rate of the element cutting edges. A solid-discrete-based method is used to precisely and efficiently identify the CWE between the end mill and the surface being machined. Then, after calibrating the specific force coef-ficients, the mechanistic milling force can be obtained. During the validation process, two practical operations, three-axis flank milling of a vertical surface and five-axis flank milling of a nondevelopable ruled surface, are conducted. Comparisons between predicted and measured cutting forces demonstrate the reliability of the proposed cutting force model.     

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.     

三元流叶轮的电弧铣削与机械铣削组合加工

首先介绍了一种实现电弧与铣削组合的加工方法及装备。其次,为验证电弧加工在航空部件生产方面的能力及其对后续精加工工艺的友好性,利用自研的高速电弧放电与机械铣削组合加工专用机床,以具有复杂曲面特征的三元流叶轮样件为例进行五轴电弧铣削与机械铣削组合加工试验研究。结果表明,合理安排电弧加工工序,可以在实现材料高效去除的同时,取得较优的表面质量,电弧铣削中最大材料去除率达14500mm^3/min,小能量电弧加工完成后的样件表面粗糙度R_a为12.5μm,硬度为69.4HRB,较基体硬度未有明显变化,可以很好地适应切削加工要求。后续机械铣削加工过程中,刀具磨损小、加工状态稳定,最终获得粗糙度R_a1.2μm的加工表面,且由于切削余量小,有效抑制了加工变形,样件加工结果达到设计要求,充分展现了该组合加工工艺应用于具有复杂形貌特征的航空发动机零部件制造方面的可行性。     

基于粘弹性材料的五轴铣削加工被动抑振技术

针对薄壁件在铣削过程中极易出现颤振,且动力学特性快速变化导致切削稳定性多变的特点,研究基于粘弹性材料的被动阻尼技术,以增加薄壁零件阻尼、提升切削稳定性。提出阻尼层、约束层以及质量层的设计方案,模态试验表明该技术能大幅提升薄壁件阻尼,且对多阶振动模态有抑制作用。最后,将其应用于薄壁S样件的五轴铣削加工试验,多组切削参数下的试验结果表明,工件切削振动幅值最大可下降约97%。     

Design and implementation of five-axis transformation function in CNC system

To implement five-axis functions in CNC system, based on domestic system Lan Tian series, an improved design method for the system software structure is proposed in this paper. The numerical control kernel of CNC system is divided into the task layer and the motion layer. A five-axis transformation unit is integrated into the motion layer. After classifying five-axis machines into different types and analyzing their geometry information, the five-axis kinematic library is designed according to the abstract factory pattern. Furthermore, by taking CA spindle- tilting machine as an example, the forward and the inverse kinematic transformations are deduced. Based on the new software architecture and the five-axis kinematic library, algorithms of RTCP （rotation tool center point control） and 3D radius compensation for end-milling are designed and realized. The milling results show that, with five-axis functions based on such software struc- ture, the instructions with respect to the cutter＇s position and orientation can be directly carried out in the CNC system.     

整体叶盘铣削数控编程与加工技术

整体叶盘有良好的结构完整性、轻质化、装配环节少、装配精度高等优点,已被广泛应用于航空发动机中。根据整体叶盘的切削加工特征,将其简化为整体叶盘基准件,从数控编程和加工技术两方面实现整体叶盘的高质量加工。首先,利用Hyper MILL软件对整体叶盘基准件进行数控编程,优化获得理想的刀具路径,保证高效高质量的零件加工。然后,利用DMU-70V五轴加工中心对钛合金TC4整体叶盘基准件进行切削加工,在整体叶盘基准件叶片和流道几何特征的精加工时,选用不同型号的立铣刀,并监测加工过程中的切削力。最后,对加工后叶片和流道加工表面形貌进行测试分析,并结合切削力对比分析国产刀具和进口刀具对钛合金整体叶盘的切削加工性能。     

Efficiently constructing collision-free regions of tool orientations for holder in five-axis machining of blisk

Blisks with the integral structure are key parts used in new jet engines to promote the performance of aircrafts, which also increases the complexity of tool orientation planning in the five-axis machining. It is an essential task to find the collision-free tool orientation when the tool holder is pushed deep into the channel of blisk to increase rigidity and reduce vibration. Since the radius of the holder varies with the height, the line-visibility is no longer applicable when constructing collision-free regions of tool orientation. In this paper, a method of constructing collision-free regions without interference checking is proposed. The work of finding collision-free regions resorts to solving the local contact curves on the checking surfaces of blisk. And it further transforms into searching the locally tangent points (named critical points) between the holder and surface. Then a tracking-based algorithm is proposed to search the sample critical points on these local contact curves. And the corresponding critical vectors are also calculated synchronously. Besides, the safety allowance, discrete precision and acceptable deviation are introduced in the algorithm to ensure accuracy by controlling the angle between two adjacent critical vectors properly. After that, the searched critical vectors are mapped orderly to two-dimensional space and the collision-free regions are constructed. This method is finally verified and compared with a referenced method. The results show that the proposed method can efficiently construct collision-free regions for holder under the given accuracy.     

Elliptical model for surface topography prediction in five-axis flank milling

In five-axis flank milling operations, the intersecting surfaces of different cutting edges create roughness on the milled surfaces that cannot be ignored in situations with strict requirements, especially in aeronautical manufacturing. To focus on motion problems in milling operations, this paper presents a new model that utilizes elliptical paths as cutting edge trajectories on 3D surface topography machined by peripheral milling. First, the cutter parallel axis offset and location angle are considered, which change the location of the ellipse center and intersection point of the cutting edges. Then, through the proposed model, the predicted surface topography is obtained, and the factors that affect the development tendency of roughness are analyzed. Next, the effects of the cutter location position (CLP) geometric parameters, cutter parallel axis offset and curvature on the roughness are evaluated by a numerical simulation. Finally, machining tests are carried out to validate the model predictions, and the results show that the surface topography predictions correspond well with the experimental results.     

五轴数控机床后置处理算法研究

五轴数控加工技术基于五轴数控编程理论,对五轴机床的结构形式和运动特性进行分析,通过后置算法求解,得到后置处理坐标转换公式,并将前置处理产生的刀位数据文件(CLFS)转换成机床执行的CNC程序,再利用Visual Basic语言编程创建坐标转换界面,实现数控程序自动转换。