• CN:11-2187/TH
  • ISSN:0577-6686

›› 2013, Vol. 49 ›› Issue (6): 171-178.

• 论文 • 上一篇    下一篇

基于动力学响应的球头刀五轴铣削表面形貌仿真

梁鑫光;姚振强   

  1. 上海交通大学机械与动力工程学院;上海交通大学机械系统与振动国家重点实验室
  • 发布日期:2013-03-20

Dynamic-based Simulation for Machined Surface Topography in 5-axis Ball-end Milling

LIANG Xinguang;YAO Zhenqiang   

  1. School of Mechanical Engineering, Shanghai Jiao Tong University State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University
  • Published:2013-03-20

摘要: 针对自由曲面球头刀五轴铣削中刀具与工件复杂的位姿关系,利用球头铣削刃的三维次摆线轨迹,提出一种在工件表面等距离间隔缓存残留高度、在刀具端等时间间隔缓存振动响应的双缓存离散机制,分别实现五轴铣削中的名义加工表面形貌建模与系统动态响应轨迹仿真。在此基础上,以切削刃经过工件表面残留区域的时间信息为纽带,利用系统瞬时动态位移响应的插值信息对已加工表面法向残留高度进行修正,建立考虑铣削系统动力学响应的已加工表面形貌预测模型。以变切深、变转速、恒定的刀具倾角与每齿进给量所进行的验证试验表明,提出的球头刀五轴铣削表面形貌建模方法可有效预测颤振工况与稳定铣削工况的加工表面形貌与纹理特征。

关键词: 表面形貌仿真, 动态响应, 球头刀, 五轴铣削

Abstract: Focusing on the complexity of the relative motion between cutter and workpiece in five-axis milling, a 3D trochoid mechanism is adopted to describe the actual tooth trajectory of the ball-end cutting edge. A kind of two-buffer mechanism is proposed to calculate residual height. One is established to determine each spatial buffer point which is discretized by a constant interval on workpiece surface, the other is built in cutter centre to simulate system dynamic response for each time interval. Thus, the nominal machined surface topography and system vibration trajectory can be calculated respectively. According to the exact time when cutting edge passing by the discretized point of the residual surface, the corresponding instantaneous vibration response can be interpolated and used to update the nominal residual height so that the prediction model of surface topography can be established with the consideration of milling system dynamic response. Validation tests are carried out with the varying cutting depth, increasing spindle speed, constant lead angle and fixed feed rate. It indicates that the proposed method can be used to predict surface topography accurately and distinguish stable milling status from chatter effectively.

Key words: 5-axis milling, Ball-end cutter, Dynamical response, Surface topography simulation

中图分类号: