基于降维映射的五轴U摆线铣削刀轨生成研究

doi:10.3901/JME.2024.05.362

机械工程学报 ›› 2024, Vol. 60 ›› Issue (5): 362-377.doi: 10.3901/JME.2024.05.362

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基于降维映射的五轴U摆线铣削刀轨生成研究

冯景洋¹, 魏兆成¹, 王敏杰¹, 舒鑫², 张勇², 雍建华²

1. 大连理工大学精密与特种加工教育部重点实验室大连 116024;
2. 沈阳鼓风机集团股份有限公司沈阳 110869

收稿日期:2023-03-09 修回日期:2023-11-25 出版日期:2024-03-05 发布日期:2024-05-30
通讯作者: 魏兆成，男，1981年出生，博士，副教授。主要研究方向为复杂曲面铣削力学/动力学。E-mail:wei_zhaocheng@dlut.edu.cn
作者简介:冯景洋，男，1992年出生，博士研究生。研究方向为复杂曲面加工。E-mailfengjingyang@mail.dlut.edu.cn；王敏杰，男，1958年出生，博士，教授，博士研究生导师。主要研究方向为先进制造技术、模具技术。E-mailmjwangg@dlut.edu.cn
基金资助:
国家自然科学基金(U1908231，52075076)和中央高校基本科研业务费专项资金(DUT21LAB107)资助项目。

Research on Cutter Path Generation for 5-Axis U Cycloid Milling Based on Dimension Reduction Mapping

FENG Jingyang¹, WEI Zhaocheng¹, WANG Minjie¹, SHU Xin², ZHANG Yong², YONG Jianhua²

1. Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian 116024;
2. Shenyang Blower Works Group Corporation, Shenyang 110869

Received:2023-03-09 Revised:2023-11-25 Online:2024-03-05 Published:2024-05-30

摘要/Abstract

摘要： 刀具轨迹生成作为数控加工的重要组成部分，是包含铣削方式、刀具工件结构以及加工余量等多因素在内的复杂体系。U摆线铣削是在摆线铣削基础上结合侧铣加工特性的走刀策略，能够以大轴向切深完成粗加工，平稳切入切出的走刀形式可以有效平滑切削力，分散局部载荷。以整体叶轮流道为目标，提出一种基于降维映射的U摆线铣削刀轨生成方法。建立U摆线铣削几何模型，定义摆线表征参数并给出摆线残留量计算方法。根据刀具运动规律将轨迹离散为系列微元，以刀具与前一刀轨迹的交点为划分依据将轨迹划分为多个区域，分别获得相应摆线位置角下刀-工包角计算方法。安排了系列实验，验证了U摆线铣削在切削力及刀具磨损方面的加工优势。结合U摆线铣削特征建立铣削边界预处理方法，考虑到三维空间刀具轨迹计算复杂，定义空间几何域及降维参数域，在此基础上给出平铺微弧的降维映射方法并分别在不同摆线区间计算降维轨迹。为获得无干涉U摆线铣削刀轴矢量，借助等参数方程建立双向比例域映射算法，通过求解系列偏转角度实现任意矢量逆映射。最后将轨迹矩阵编码为通用机床语言，通过仿真算例及铣削实验验证刀轨生成方法的可行性。

关键词: U摆线铣削, 降维映射, 刀-工包角, 五轴铣削, 刀具轨迹

Abstract: As an important part of NC machining, cutter path generation is a complex system including many factors such as milling mode, tool workpiece structure and machining allowance. U cycloid milling is a cutter path strategy that integrates the advantages of cycloid milling and flank milling. It can complete rough machining with large axial cutting depth. The cutter path form of gentle cut in and cut out can effectively stable the cutting force and the local load is dispersed. Aiming at the flow path of integral impeller, a cutter path generation method for U cycloid milling based on dimension reduction mapping is proposed. The geometric model of U cycloid milling is established, the cycloid feature parameters are defined, and the calculation method of cycloid residue is given. According to the rule of tool motion, the path is discretized into a series of micro elements. Based on the intersection of the tool and the previous cutter path, the path is divided into multiple regions, and the calculation methods of the cutter-workpiece wrap angle under the corresponding cycloidal position angle are obtained respectively. Combined with U cycloid milling features, the milling boundary preprocessing method is established. Considering the complexity of cutter path calculation in 3D space, the space geometry domain and dimension reduction parameter domain are defined. On this basis, the dimension reduction mapping method of tiled small arc segment is given and the dimension reduction paths are calculated in different cycloid intervals. In order to obtain interference free U cycloid milling cutter axis vector, a double-action ratio domain mapping algorithm is established by using the isoparametric equation, and arbitrary vector inverse mapping is realized by solving a series of deflection angles. Finally, the trajectory matrix is coded into general machine tool language, and the feasibility of the strategy is verified through simulation studies and milling experiments.

Key words: U cycloid milling, dimension reduction mapping, cutter-workpiece wrap angle, 5-axis milling, cutter path

中图分类号:

TG506

冯景洋, 魏兆成, 王敏杰, 舒鑫, 张勇, 雍建华. 基于降维映射的五轴U摆线铣削刀轨生成研究[J]. 机械工程学报, 2024, 60(5): 362-377.

FENG Jingyang, WEI Zhaocheng, WANG Minjie, SHU Xin, ZHANG Yong, YONG Jianhua. Research on Cutter Path Generation for 5-Axis U Cycloid Milling Based on Dimension Reduction Mapping[J]. Journal of Mechanical Engineering, 2024, 60(5): 362-377.

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基于降维映射的五轴U摆线铣削刀轨生成研究

Research on Cutter Path Generation for 5-Axis U Cycloid Milling Based on Dimension Reduction Mapping

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