九轴联动叶片双刀对顶铣削的非线性误差分析与控制算法

doi:10.3901/JME.2020.03.197

机械工程学报 ›› 2020, Vol. 56 ›› Issue (3): 197-206.doi: 10.3901/JME.2020.03.197

九轴联动叶片双刀对顶铣削的非线性误差分析与控制算法

宋冬冬, 薛飞, 赵万华, 卢秉恒

西安交通大学机械制造系统工程国家重点实验室西安 710049

收稿日期:2019-03-11 修回日期:2019-08-09 出版日期:2020-02-05 发布日期:2020-04-09
通讯作者: 薛飞(通信作者),男,1982年出生,博士,高级工程师。主要研究方向为叶片高效加工工艺及装备。E-mail:xuefei82@mail.xjtu.edu.cn;赵万华(通信作者),男,1965年出生,博士,长江学者特聘教授,博士研究生导师。主要研究方向为基于运行大数据的装备智能化基础研究和增减材成形过程中的材料力学行为表征。E-mail:whzhao@mail.xjtu.edu.cn
作者简介:宋冬冬,男,1984年出生,博士研究生,主要研究方向为自由曲面的轨迹规划。E-mail:sdd1213@stu.xjtu.edu.cn
基金资助:
国家自然科学基金（51605373）和国家科技重大专项（2018ZX04004001）资助项目。

Analysis and Control Algorithm of Non-linear Error for Nine-axis Synchronize Milling Blades with Twin-cutters

SONG Dongdong, XUE Fei, ZHAO Wanhua, LU Bingheng

State Key Laboratory for Manufacturing Systems Engineering, Xi'an Jiaotong University, Xi'an 710049

Received:2019-03-11 Revised:2019-08-09 Online:2020-02-05 Published:2020-04-09

摘要/Abstract

摘要： 针对双刀对顶铣削线性插补过程中三个旋转运动引起切触点实际运动轨迹与理论规划轨迹不重合的现象，为了保证工件的表面加工质量，提出了减小双刀对顶铣削中非线性误差的轨迹优化算法。针对双刀具的位置约束关系，建立九轴联动机床的运动学同步转换模型。结合工件表面的几何特征，阐述了切触点间非线性误差的理论表征方法，并建立旋转轴引起非线性误差的简化计算模型；以双刀对顶铣削轨迹线上非线性误差和加工误差为优化目标，建立双刀对应切触点同步插值的优化模型。以典型汽轮机叶片双刀对铣加工为例，同步修正了双刀对应线性插补轨迹线上的切触点，仿真和试验结果显示，该方法有效减小了加工过程中的非线性误差，可提高叶片型面的加工精度。

关键词: 双刀铣削, 非线性误差, 轨迹优化

Abstract: There are three rotary motions in linear interpolation of twin-tool milling process, which causes the phenomenon that the actual motion trajectory of the cutting contact point does not coincide with the theoretical planning trajectory. In order to ensure surface machining quality of the workpiece, the path optimization algorithm for reducing the non-linear error in twin-tool milling process is proposed. Considering the position constraint relationship of two cutters, the kinematic synchronous conversion model of nine-axis machine tool is suggested. Based on the geometrical feature of the workpiece surface, the theoretical characterization method of non-linear error between the cutting contact points is researched, and the simplified calculation model of the non-linear errors caused by the rotational motion is built. For effectively controlling the non-linear error and the machining error of the twin-tool milling path, the optimization model is established to realize the synchronous interpolation of opposite cutting contact points for the two cutters. Then, the cutting contact points in twin-tool milling path is simultaneously corrected for a typical turbine blade based on the method. The results of simulation and experiment show that the non-linear error of twin-tool milling is reduced. And the feasibility of proposed method is verified which can be used to improve the machining accuracy of blade profile.

Key words: twin-tool milling, non-linear error, path optimization

中图分类号:

TG156

宋冬冬, 薛飞, 赵万华, 卢秉恒. 九轴联动叶片双刀对顶铣削的非线性误差分析与控制算法[J]. 机械工程学报, 2020, 56(3): 197-206.

SONG Dongdong, XUE Fei, ZHAO Wanhua, LU Bingheng. Analysis and Control Algorithm of Non-linear Error for Nine-axis Synchronize Milling Blades with Twin-cutters[J]. Journal of Mechanical Engineering, 2020, 56(3): 197-206.

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九轴联动叶片双刀对顶铣削的非线性误差分析与控制算法

Analysis and Control Algorithm of Non-linear Error for Nine-axis Synchronize Milling Blades with Twin-cutters

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