• CN:11-2187/TH
  • ISSN:0577-6686

机械工程学报

• 数字化设计与制造 • 上一篇    下一篇

基于机床运动学约束球头刀多轴加工刀轴矢量优化方法

徐汝锋1,2,3,  陈志同2,  孟凡军2,  张云2,  吴献珍3   

  1. 1. 山东理工大学机械工程学院  淄博  255049;
    2. 北京航空航天大学机械工程及自动化学院  北京  100191;
    3. 中航工业昌河飞机工业(集团)有限责任公司  景德镇  333000
  • 收稿日期:2014-12-05 修回日期:2015-06-05 出版日期:2015-12-05 发布日期:2015-12-05
  • 通讯作者: 徐汝锋,男,1980年出生,博士,讲师。主要研究方向为复杂曲面多轴数控加工技术。 E-mail:xurufeng2003@126.com
  • 作者简介:徐汝锋,男,1980年出生,博士,讲师。主要研究方向为复杂曲面多轴数控加工技术。 E-mail:xurufeng2003@126.com
  • 基金资助:
    国家自然科学基金(51105026)、高等学校博士学科点专项科研基金(20111102110021)和山东省优秀中青年科学家科研奖励基金(BS2013ZZ002)资助项目

Tool Orientation Optimization Method Based on Kinematics Constraints of the Machine Tool in Multi-axis Machining with a Ball-end Cutter

XU Rufeng1,2,3,  CHEN Zhitong2,  MENG Fanjun2,  ZHANG Yun2,  WU Xianzhen3   

  1. 1. School of Mechanical Engineering, Shandong University of Technology, Zibo 255049;
    2. School of Mechanical Engineering and Automation, Beihang University, Beijing 100191;
    3. Changhe Aircraft Industries Group Co., Ltd., Jingdezhen 333000
  • Received:2014-12-05 Revised:2015-06-05 Online:2015-12-05 Published:2015-12-05

摘要: 针对目前航空发动机叶片进排气边加工精度和表面质量较差的问题,提出了一种基于机床运动学约束球头刀多轴加工刀轴矢量优化方法。建立刀位优化变量与刀位数据之间的关系方程,同时建立刀位数据与机床回转轴角度之间的运动变换方程,从而推导出刀位优化变量与机床回转轴角度之间的关系方程。通过求解上述方程得到球头刀多轴加工复杂曲面的刀轴矢量计算公式。在此基础上,给出球头刀多轴加工刀轴矢量优化方法和刀轨生成方法。同时,以某航空发动机叶片为例,分析了本文算法和Sturz算法对机床回转轴角度的影响。分别利用本文算法和Sturz算法生成该叶片进气边加工的刀轨,并在五轴数控机床上进行加工试验。试验结果表明,该算法能够避免加工过程中机床回转轴的大幅波动,使机床轴运动更加平稳和光滑,从而提高曲面的加工质量和加工效率,具有一定的实际应用价值。

关键词: 刀轴矢量, 多轴加工, 复杂曲面, 球头刀, 运动学约束

Abstract: In order to solve the problem of the poor machining quality of the leading and trailing edge surface of the aero engine blade, a tool orientation optimization method based on the kinematics constraints of the machine tool in multi-axis machining with a ball-end cutter is presented. A relation equation between the design variables of tool position and cutter location (CL) data is established, and a coordinate transformation equation between CL data and rotary axes of the machine tool is established. From the above two equations, a relation equation between the design variables of tool position and rotary axes of the machine tool is derived. Through solving the above relation equation, formulas for calculating tool position and tool orientation during the machining of sculptured surfaces with a ball-end cutter are derived. On this basis, a tool orientation optimization method and a tool path generation method for multi-axis machining with a ball-end cutter is presented. Besides, analyze the influence of the proposed method and Sturz method on rotary axes of the machine tool. Tool paths of the leading edge surface of an aero engine blade are generated by the proposed method and the Sturz method, respectively, and cutting trials are carried out on a five-axis machine tool. Experimental results show that the proposed method can avoid abrupt change of rotary axes of the machine tool and make the movement of machine axes more stable and smoother, and further obtain better machining quality and higher machining efficiency. Consequently, the proposed method will have important practical value.

Key words: ball-end cutter, kinematics constraints, multi-axis machining, sculptured surfaces, tool orientation