复杂曲面高性能侧铣加工技术与方法研究
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摘要
随着我国航空航天、国防、运载和能源等领域不断拓展,一些起主导作用的精密复杂零件对加工的效率、成形的精度以及成品率等指标提出了更高要求。这些曲面类零件多需利用五轴加工中心进行加工。然而,传统加工方式大都从几何学层面规划刀具路径、设定进给速度,忽视了加工过程的动力学性能。实际中,铣削加工不仅仅是一个几何过程,也是物理过程。保证零件几何形状、成形表面精度的同时,维持加工系统的稳定、最大限度提高材料去除率,已经成为高性能加工的基本要求。为此,本文以高性能侧铣加工为研究对象,对其中的铣削力预测、被加工表面几何误差的计算和切削稳定性等关键技术进行了研究。
1、建立刀具坐标系、旋转坐标系以及工件坐标系,分析了刀具跳动产生的原因及相关参数,给出了包含刀具跳动的一般机床坐标变换基础；进而以通用整体刀具为例给出了刀具切削刃上一点由刀具坐标系到旋转坐标系的坐标变换,并由此推导出了含跳动的刀具切削刃绕机床主轴旋转形成旋转体表面,同时给出了刀具切削刃上一点由旋转坐标系到工件坐标系的机床坐标变换。
2、建立了适用于任意五轴加工轨迹的铣削力模型。依据刀位点、刀位矢量等刀位路径信息以及进给率、主轴转速等工艺参数信息建立了刀具切削刃真实空间扫掠面；综合考虑加工参数以及跳动的影响,建立基于刀具切削刃真实空间扫掠包络面的精确瞬时未变形切削厚度模型；结合该瞬时未变形切削厚度模型,建立高性能侧铣加工五轴任意轨迹铣削力模型,并推导出了侧铣加工铣削力系数识别模型,给出了刀具/工件组合的侧铣切削力系数曲线；以上述模型为基础,对跳动参数进行了分析和识别,给出了相应的实验结果,并对本文提出的铣削力精确模型和传统铣削力模型之间的差别进行了分析；利用平底立铣刀进行了一系列三轴、五轴加工实验用以验证本铣削力预测模型的精确性和有效性。
3、建立了源于跳动的被加工表面几何误差求解模型并提出相应刀位补偿方法。结合跳动求解出刀位路径面上任何位置处刀具切削刃旋转体表面任一点处的速度矢量和法矢量,并利用速度矢量和法矢量间的空间位置关系以及包络原理推导出了刀具沿刀位路径的扫掠包络面；进而通过对该扫掠包络面和被加工表面最近距离分析,得到了源于刀具跳动的被加工表面几何误差；在此基础上,分析了刀具跳动各参数及刀具切削刃个数对上述被加工表面几何误差的影响规律；并利用最小二乘刀位规划原理对刀位路径面进行优化,结果表明该刀位规划方法能有效降低源于跳动的被加工表面几何误差。
4、提出计算动态铣削系统稳定域的三阶全离散方法。在分析了动态切削系统颤振产生原因的基础上,建立了切削系统颤振的数学模型,并利用三阶全离散法对该数学模型进行求解,同时讨论了三阶全离散法的收敛性能,得到了其动态侧铣稳定性叶瓣图；考虑到实际加工中跳动诱导的侧铣颤振的多重再生性,建立了基于多重再生效应的颤振数学模型,并利用上述三阶全离散法基本原理计算跳动存在时侧铣动态加工的稳定性叶瓣图,得到了跳动参数对稳定叶瓣图的影响规律。
最后以一典型结构比例件为例,对提出的被加工表面几何误差以及相应的刀位规划方法和切削稳定性叶瓣图计算方法进行了实例验证。可以发现,利用本文提出的方法可以有效降低被加工表面质量的同时,提高材料去除率,满足高性能加工基本要求。
With the development of aerospace, national defense, carrier and energy fields, some key workpieces with high accuracy need to improve machining efficiency and yield. These workpieces are machined using five-axis machining center. However, most classical tool path planning and feed rate scheduling methods only consider the machining process from a purely geometric perspective, and rarely take into account kinematic and mechanical properties of machine systems. Actually, the machining process is not only a geometry machining process, but also a physical machining process. Ensuring geometry accuracy, maintaining dynamic machining process stability and improving machining efficiency have been basic requirements of high performance machining. Therefore, taking high performance peripheral milling as research objective, predicting milling force, calculating geometric error and computing of machining process stability are studied.
1、Introducing the cutter coordinate system, rotational coordinate system and workpiece coordinate system, the reason inducing the cutter runout is analyzed and the kinematic transformation basic rules of general machine are given. The transformation process of a point on the cutter edge from cutter coordinate system to the rotational coordinate system is derived. Subsequently, the rotational surface of the cutter edge about the spindle axis of machine is introduced. Simultaneously, the transformation principle of a point from rotational coordinate system to the workpiece coordinate system is derived.
2、Cutting force prediction model, which is suitable for the five axis peripheral milling, is built. Using cutter location information and process parameters, the real sweep surface of cutter edge is processed. Then, the instantaneous uncut chip thickness model is developed. On the basis of this, the cutting force model is built, and then a coefficient detective model is proposed. Subsequently, cutter runout parameters are identified using the cutting force model and experimental results are showed. The predicted values computed by the proposed cutting force prediction model are compared with that of the classical method. Results show that the method in this paper is of higher accuracy. Finally, a series of three and five axis peripheral cutting force experiment are conducted to verify the validity, efficiency and accuracy of the proposed method.
3、The geometry error induced by the cutter runout are introduced and the corresponding tool path compensation method is presented. Combining the general situation of the cutter runout, an arbitrary point's velocity vector and normal vector on the cutter edge's rotational surface about spindle axis are calculated. Utilizing the relationship between these two vectors and the envelope principle, the envelope-sweep surface along tool path is computed. Comparing the envelope surface with the machined surface, the geometry error induced by the cutter runout is calculated. Then the effect of the cutter runout parameters and the number of the cutter edges on the geometry error is studied. Finally, the error induced by the cutter runout is reduced significantly using the proposed tool path planning method.
4、A new third-order full-discretization method to compute stability lobes of dynamic milling system is presented. Based on the mathematical model of chatter, the stability lobes of dynamic machining system are calculated using the above method and the convergence property of the method is discussed. Becsuse of the existence of the cutter runout, the chatter is not induced by single regenerative effect but multiple regenerative effect. Thus this paper gives the mathematical model of multiple regenerative effect and calculates conresponding stability lobes. Finally, the influence law of the cutter runout on the stability lobes is studied.
Taking a typical scale workpiece as an example, the effectiveness of tool path planning method and stability prediction method are verified, and then the results are used to guide the machining process of the component. The results show that the accuracy of machined surface and material removal rate are improved. This meets the requirement of the high performance machining.
1、建立刀具坐标系、旋转坐标系以及工件坐标系,分析了刀具跳动产生的原因及相关参数,给出了包含刀具跳动的一般机床坐标变换基础；进而以通用整体刀具为例给出了刀具切削刃上一点由刀具坐标系到旋转坐标系的坐标变换,并由此推导出了含跳动的刀具切削刃绕机床主轴旋转形成旋转体表面,同时给出了刀具切削刃上一点由旋转坐标系到工件坐标系的机床坐标变换。
2、建立了适用于任意五轴加工轨迹的铣削力模型。依据刀位点、刀位矢量等刀位路径信息以及进给率、主轴转速等工艺参数信息建立了刀具切削刃真实空间扫掠面；综合考虑加工参数以及跳动的影响,建立基于刀具切削刃真实空间扫掠包络面的精确瞬时未变形切削厚度模型；结合该瞬时未变形切削厚度模型,建立高性能侧铣加工五轴任意轨迹铣削力模型,并推导出了侧铣加工铣削力系数识别模型,给出了刀具/工件组合的侧铣切削力系数曲线；以上述模型为基础,对跳动参数进行了分析和识别,给出了相应的实验结果,并对本文提出的铣削力精确模型和传统铣削力模型之间的差别进行了分析；利用平底立铣刀进行了一系列三轴、五轴加工实验用以验证本铣削力预测模型的精确性和有效性。
3、建立了源于跳动的被加工表面几何误差求解模型并提出相应刀位补偿方法。结合跳动求解出刀位路径面上任何位置处刀具切削刃旋转体表面任一点处的速度矢量和法矢量,并利用速度矢量和法矢量间的空间位置关系以及包络原理推导出了刀具沿刀位路径的扫掠包络面；进而通过对该扫掠包络面和被加工表面最近距离分析,得到了源于刀具跳动的被加工表面几何误差；在此基础上,分析了刀具跳动各参数及刀具切削刃个数对上述被加工表面几何误差的影响规律；并利用最小二乘刀位规划原理对刀位路径面进行优化,结果表明该刀位规划方法能有效降低源于跳动的被加工表面几何误差。
4、提出计算动态铣削系统稳定域的三阶全离散方法。在分析了动态切削系统颤振产生原因的基础上,建立了切削系统颤振的数学模型,并利用三阶全离散法对该数学模型进行求解,同时讨论了三阶全离散法的收敛性能,得到了其动态侧铣稳定性叶瓣图；考虑到实际加工中跳动诱导的侧铣颤振的多重再生性,建立了基于多重再生效应的颤振数学模型,并利用上述三阶全离散法基本原理计算跳动存在时侧铣动态加工的稳定性叶瓣图,得到了跳动参数对稳定叶瓣图的影响规律。
最后以一典型结构比例件为例,对提出的被加工表面几何误差以及相应的刀位规划方法和切削稳定性叶瓣图计算方法进行了实例验证。可以发现,利用本文提出的方法可以有效降低被加工表面质量的同时,提高材料去除率,满足高性能加工基本要求。
With the development of aerospace, national defense, carrier and energy fields, some key workpieces with high accuracy need to improve machining efficiency and yield. These workpieces are machined using five-axis machining center. However, most classical tool path planning and feed rate scheduling methods only consider the machining process from a purely geometric perspective, and rarely take into account kinematic and mechanical properties of machine systems. Actually, the machining process is not only a geometry machining process, but also a physical machining process. Ensuring geometry accuracy, maintaining dynamic machining process stability and improving machining efficiency have been basic requirements of high performance machining. Therefore, taking high performance peripheral milling as research objective, predicting milling force, calculating geometric error and computing of machining process stability are studied.
1、Introducing the cutter coordinate system, rotational coordinate system and workpiece coordinate system, the reason inducing the cutter runout is analyzed and the kinematic transformation basic rules of general machine are given. The transformation process of a point on the cutter edge from cutter coordinate system to the rotational coordinate system is derived. Subsequently, the rotational surface of the cutter edge about the spindle axis of machine is introduced. Simultaneously, the transformation principle of a point from rotational coordinate system to the workpiece coordinate system is derived.
2、Cutting force prediction model, which is suitable for the five axis peripheral milling, is built. Using cutter location information and process parameters, the real sweep surface of cutter edge is processed. Then, the instantaneous uncut chip thickness model is developed. On the basis of this, the cutting force model is built, and then a coefficient detective model is proposed. Subsequently, cutter runout parameters are identified using the cutting force model and experimental results are showed. The predicted values computed by the proposed cutting force prediction model are compared with that of the classical method. Results show that the method in this paper is of higher accuracy. Finally, a series of three and five axis peripheral cutting force experiment are conducted to verify the validity, efficiency and accuracy of the proposed method.
3、The geometry error induced by the cutter runout are introduced and the corresponding tool path compensation method is presented. Combining the general situation of the cutter runout, an arbitrary point's velocity vector and normal vector on the cutter edge's rotational surface about spindle axis are calculated. Utilizing the relationship between these two vectors and the envelope principle, the envelope-sweep surface along tool path is computed. Comparing the envelope surface with the machined surface, the geometry error induced by the cutter runout is calculated. Then the effect of the cutter runout parameters and the number of the cutter edges on the geometry error is studied. Finally, the error induced by the cutter runout is reduced significantly using the proposed tool path planning method.
4、A new third-order full-discretization method to compute stability lobes of dynamic milling system is presented. Based on the mathematical model of chatter, the stability lobes of dynamic machining system are calculated using the above method and the convergence property of the method is discussed. Becsuse of the existence of the cutter runout, the chatter is not induced by single regenerative effect but multiple regenerative effect. Thus this paper gives the mathematical model of multiple regenerative effect and calculates conresponding stability lobes. Finally, the influence law of the cutter runout on the stability lobes is studied.
Taking a typical scale workpiece as an example, the effectiveness of tool path planning method and stability prediction method are verified, and then the results are used to guide the machining process of the component. The results show that the accuracy of machined surface and material removal rate are improved. This meets the requirement of the high performance machining.
引文
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