面向高效节能的复杂曲面分区数控铣削加工优化方法
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摘要
复杂曲面加工常采用统一的切削参数和刀具路径完成整个曲面加工,未考虑复杂曲面几何特性变化对能耗和加工时间的影响关系。以复杂曲面为研究对象,根据曲面曲率特性并运用模糊聚类算法对复杂曲面进行分区。在此基础上,针对每一个分区曲面,采用正交试验方法确定能耗和加工时间综合最优的切削参数和刀具路径,即实现复杂曲面加工总能耗最低和加工时间最短。最后,将所提出的曲面分区铣削优化方法与传统曲面整体铣削方法作对比,验证了所提方法的有效性。
Traditionally,the workpiece complex surfaces were machined by a specific cutting parameters and toolpath.In fact,the dynamic curvatures of complex surfaces had major impacts on energy consumption and machining time.The workpiece complex surfaces were partitioned into several patches according to the characteristics of surface curvatures and by using fuzzy clustering algorithm.Then for each patch,a set of orthogonal experiments were designed to determine the optimal cutting parameters and toolpaths aiming to minimize the machining time and energy consumption.Finally,the effectiveness of the proposed method was demonstrated through comparison of the partitioned complex surface milling and the traditional whole complex surface milling.
Traditionally,the workpiece complex surfaces were machined by a specific cutting parameters and toolpath.In fact,the dynamic curvatures of complex surfaces had major impacts on energy consumption and machining time.The workpiece complex surfaces were partitioned into several patches according to the characteristics of surface curvatures and by using fuzzy clustering algorithm.Then for each patch,a set of orthogonal experiments were designed to determine the optimal cutting parameters and toolpaths aiming to minimize the machining time and energy consumption.Finally,the effectiveness of the proposed method was demonstrated through comparison of the partitioned complex surface milling and the traditional whole complex surface milling.
引文
[1]丁汉,朱利民.复杂曲面数字化制造的几何学理论和方法[M].北京:科学出版社,2011:4.DING Han,ZHU Limin.Geometric Theory and Methods of Digital Manufacturing of Complex Surfaces[M].Beijing:Science Press,2011:4.
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[3]RYUTA S,KEIICHI S,AKIO H.Energy Consumption of Feed Drive Systems Based on Workpiece Setting Position in Five-axis Machining Center[J].Journal of Manufacturing Science&Engineering,2018,140(2):1-7.
[4]UCHIYAMA N,OGAWA Y,ABD E K M,et al.Energy Saving in Five-axis Machine Tools Using Synchronous and Contouring Control and Verification by Machining Experiment[J].IEEE Transactions on Industrial Electronics,2015,62(9):5608-5618.
[5]XU K,LUO M,TANG K.Machine Based Energysaving Tool Path Generation for Five-axis End Milling of Freeform Surfaces[J].Journal of Cleaner Production,2016,139:1207-1223.
[6]李丽,邓兴国,尚川博.面向能效的曲面数控加工刀具路径优化方法[J].机械工程学报,2017,53(11):184-194.LI Li,DENG Xingguo,SHANG Chuanbo.Optimization of Tool Paths for NC Machining of Energyefficient Surfaces[J].Journal of Mechanical Engineering,2017,53(11):184-194.
[7]GIRI V,BEZBARUAH D,BUBNA P,et al.Selection of Master Cutter Paths in Sculptured Surface Machining by Employing Curvature Principle[J].International Journal of Machine Tools&Manufacture,2005,45(10):1202-1209.
[8]van TUONG N,POKORNY P.A Practical Approach for Partitioning Free-form Surfaces[J].Taylor Francis Inc.,2010,23(11):992-1001.
[9]ROMAN A,BAROCIO E,HUEGEL J C,et al.Rolling Ball Method Applied to 31212axis Machining for Tool Orientation and Positioning and Path Planning[J].Advances in Mechanical Engineering,2015,7(12):1-12.
[10]林洁琼.自由曲面分片研抛与轨迹规划的研究[D].长春:吉林大学,2005.LIN Jieqiong.Study on Discretization and Trajectory Planning of Freeform Surface[D].Changchun:Jilin University,2005.
[11]刘旭.基于动态加工特征的复杂曲面加工方法[D].南京:南京航空航天大学,2015.LIU Xu.Complex Surface Processing Method Based on Dynamic Machining Feature[D].Nanjing:Nanjing University of Aeronautics and Astronautics,2015.
[12]陈良骥.复杂曲面数控加工相关技术[M].北京:知识产权出版社,2011:56.CHEN Liangji.Technology Related to Complex Surface CNC Machining[M].Beijing:Intellectual Property Publishing House,2011:56.
[13]蔡静颖.模糊聚类算法及应用[M].北京:冶金工业出版社,2015:38-42.CAI Jingying.Fuzzy Clustering Algorithm and Application[M].Bejing:Metallurgical Industry Press,2015:38-42.
[14]于洋.五轴自由曲面NC加工刀路优化及误差控制[M].北京:国防工业出版社,2015:66-96.YU Yang.Tool Path Optimization and Error Control of Five-axis NC Machining for Freeform Surfaces[M].Beijing:National Defense Industry Press,2015:66-96.(编辑袁兴玲)
[2]LI L,CHEN B,LIU F,et al.Complexity Analysis and Calculation for Sculptured Surface in Multi-axis CNC Machining Based on Surface Subdivision[J].International Journal of Advanced Manufacturing Technology 2014,71(5/8):1433-1444.
[3]RYUTA S,KEIICHI S,AKIO H.Energy Consumption of Feed Drive Systems Based on Workpiece Setting Position in Five-axis Machining Center[J].Journal of Manufacturing Science&Engineering,2018,140(2):1-7.
[4]UCHIYAMA N,OGAWA Y,ABD E K M,et al.Energy Saving in Five-axis Machine Tools Using Synchronous and Contouring Control and Verification by Machining Experiment[J].IEEE Transactions on Industrial Electronics,2015,62(9):5608-5618.
[5]XU K,LUO M,TANG K.Machine Based Energysaving Tool Path Generation for Five-axis End Milling of Freeform Surfaces[J].Journal of Cleaner Production,2016,139:1207-1223.
[6]李丽,邓兴国,尚川博.面向能效的曲面数控加工刀具路径优化方法[J].机械工程学报,2017,53(11):184-194.LI Li,DENG Xingguo,SHANG Chuanbo.Optimization of Tool Paths for NC Machining of Energyefficient Surfaces[J].Journal of Mechanical Engineering,2017,53(11):184-194.
[7]GIRI V,BEZBARUAH D,BUBNA P,et al.Selection of Master Cutter Paths in Sculptured Surface Machining by Employing Curvature Principle[J].International Journal of Machine Tools&Manufacture,2005,45(10):1202-1209.
[8]van TUONG N,POKORNY P.A Practical Approach for Partitioning Free-form Surfaces[J].Taylor Francis Inc.,2010,23(11):992-1001.
[9]ROMAN A,BAROCIO E,HUEGEL J C,et al.Rolling Ball Method Applied to 31212axis Machining for Tool Orientation and Positioning and Path Planning[J].Advances in Mechanical Engineering,2015,7(12):1-12.
[10]林洁琼.自由曲面分片研抛与轨迹规划的研究[D].长春:吉林大学,2005.LIN Jieqiong.Study on Discretization and Trajectory Planning of Freeform Surface[D].Changchun:Jilin University,2005.
[11]刘旭.基于动态加工特征的复杂曲面加工方法[D].南京:南京航空航天大学,2015.LIU Xu.Complex Surface Processing Method Based on Dynamic Machining Feature[D].Nanjing:Nanjing University of Aeronautics and Astronautics,2015.
[12]陈良骥.复杂曲面数控加工相关技术[M].北京:知识产权出版社,2011:56.CHEN Liangji.Technology Related to Complex Surface CNC Machining[M].Beijing:Intellectual Property Publishing House,2011:56.
[13]蔡静颖.模糊聚类算法及应用[M].北京:冶金工业出版社,2015:38-42.CAI Jingying.Fuzzy Clustering Algorithm and Application[M].Bejing:Metallurgical Industry Press,2015:38-42.
[14]于洋.五轴自由曲面NC加工刀路优化及误差控制[M].北京:国防工业出版社,2015:66-96.YU Yang.Tool Path Optimization and Error Control of Five-axis NC Machining for Freeform Surfaces[M].Beijing:National Defense Industry Press,2015:66-96.(编辑袁兴玲)