椭球头铣刀设计及其刀具路径生成算法
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摘要
随着航空航天、汽车模具等领域内型面复杂程度的日益增大,目前对不同形状、不同性能刀具的需求也不断增加。设计了一种刀具端部切削刃所在回转面为椭球面的整体铣刀,以下称为椭球头铣刀。建立了椭球头铣刀参数化模型,为刀具的参数化设计提供理论基础。提出了椭球头铣刀的三种切削刃曲线模型:等螺旋角切削刃、正交螺旋形切削刃和新型切削刃,精准的刀具切削刃曲线模型为椭球头铣刀的精准制造提供了理论依据。提出了椭球头铣刀三轴端铣加工曲面的刀具路径生成算法,并通过试验验证了刀具路径生成算法的正确性和可行性,分析了刀具的切削性能并验证了椭球头铣刀的优势,为椭球头铣刀的推广应用提供了理论基础。对椭球头铣刀的参数化设计和应用研究,也为其他新型刀具的设计和应用提供了方法和理论依据。
With the increasing complexity of the workpiece surfaces in aerospace and automotive mold and other areas, more and more tools with different shapes and performance have been needed. A kind of cutting tool is designed with ellipsoid revolving surface of tool's end, which called ellipsoid end mill as follows. The parametric geometric model of ellipsoid end mill is established, which provides a theoretical basis for the parametric design of the tool. Three kinds of cutting edge curves of ellipsoid end mill are proposed(cutting edge with constant helix angle, the orthogonal spiral cutting edge and a novel cutting edge). Accurate tool cutting edge curve models provide a theoretical basis for the precise manufacture of ellipsoid end mill. The path generation algorithm of three-axis NC machining tool path of ellipsoid end mill is given and the correctness and feasibility of the algorithm are verified by experiments. The cutting performance of ellipsoid end mill is analyzed and the advantage is verified as well, which provides technical support for the extension and application of ellipsoid end mill. The parametric design and application research for ellipsoid end mill provides method and theoretical provide the basis for other new types of tools.
With the increasing complexity of the workpiece surfaces in aerospace and automotive mold and other areas, more and more tools with different shapes and performance have been needed. A kind of cutting tool is designed with ellipsoid revolving surface of tool's end, which called ellipsoid end mill as follows. The parametric geometric model of ellipsoid end mill is established, which provides a theoretical basis for the parametric design of the tool. Three kinds of cutting edge curves of ellipsoid end mill are proposed(cutting edge with constant helix angle, the orthogonal spiral cutting edge and a novel cutting edge). Accurate tool cutting edge curve models provide a theoretical basis for the precise manufacture of ellipsoid end mill. The path generation algorithm of three-axis NC machining tool path of ellipsoid end mill is given and the correctness and feasibility of the algorithm are verified by experiments. The cutting performance of ellipsoid end mill is analyzed and the advantage is verified as well, which provides technical support for the extension and application of ellipsoid end mill. The parametric design and application research for ellipsoid end mill provides method and theoretical provide the basis for other new types of tools.
引文
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[19]DING S,MANNAN M,POO A N,et al.Adaptive iso-planar tool path generation for machining of free-form surfaces[J].Computer-Aided Design,2003,35(2):141-153.
[20]陈英.模具高速铣削刀具轨迹规划与工艺参数优选技术的研究[D].长春:吉林大学,2012.CHEN Ying.Research on tool path planning and process parameter optimization technology of high speed milling for die[D].Changchun:Jilin University,2012.
[21]王海春.曲面加工刀具轨迹生成技术的研究与实现[D].武汉:武汉理工大学,2009.WANG Haichun.Research and implementation for tool path generation of free form surfaces machining[D].Wuhan:Wuhan University of Technology,2009.
[2]JUN C S,CHA K,LEE Y S.Optimizing tool orientations for 5-axis machining by configuration-space search method[J].Computer-Aided Design,2003,35(6):549-566.
[3]TOURNIER C,DUC E.Iso-scallop tool path generation in 5-axis milling[J].AMT,2005,25(9-10):867-875.
[4]FAN J,BALL A.Quadric method for cutter orientation in five-axis sculptured surface machining[J].International Journal of Machine Tools and Manufacture,2008,48(7-8):788-801.
[5]刘献礼,姜志鹏,李茂月,等.基于残留高度设计的模具加工用新型圆角端铣刀[J].机械工程学报,2015,51(5):192-204.LIU Xianli,JIANG Zhipeng,LI Maoyue,et al.New rounded end mill for mold processing based on scallop-height[J].Journal of mechanical engineering,2015,51(5):192-204.
[6]姜彦翠,刘献礼,丁云鹏,等.汽车大型覆盖件淬硬钢模具切削加工技术[J].哈尔滨理工大学学报,2013,18(1):7-13.JIANG Yancui,LIU Xianli,DING Yunpeng,et al.Machining technology of hardened steel molds of automobile large covering[J].Journal of Harbin University of Science and Technology,2013,18(1):7-13.
[7]JIN M,GOTO I,WATANABE T,et al.Development of CBN ball-nosed end mill with newly designed cutting edge[J].Journal of Materials Processing Technology,2007(192-193):48-54.
[8]BY CHEN J S,HUANG Y K,CHEN M S.Feedrate optimization and tool profile modification for the high-efficiency ball-end milling process[J].International Journal of Machine Tools and Manufacture,2005,45(9):1070-1076.
[9]张安山.汽车模具小曲率面宽行加工技术研究及其刀具开发[D].哈尔滨:哈尔滨理工大学,2015.ZHANG Anshan.Research on large machining strip&tool design for small-curvature surface of automobile mold[D].Harbin:Harbin University of Science&Technology,2015.
[10]刘献礼,马晶,岳彩旭,等.汽车模具凸曲面精加工极限切削深度预测[J].机械工程学报,2015,51(2):117-126.LIU Xianli,MA Jing,YUE Caixu,et al.Limit cutting depth prediction for automobile dies finishing machining of convex surface[J].Journal of Mechanical Engineering,2015,51(2):117-126.
[11]孙玉文,徐金亭,任斐,等.复杂曲面高性能多轴精密加工技术与方法[M].北京:科学出版社,2014.SUN Yuwen,XU Jinting,REN Fei,et al.High performance multi-axis precisely machining complex surface technology and process[M].Beijing:Science Press,2014.
[12]XU J T,JIN C N.Boundary-conformed machining for trimmed free-form surfaces based on mesh mapping[J].International Journal of Computer Integrated Manufacturing,2013,26(8):720-730.
[13]SARKAR S,DEY P P.A new iso-parametric machining algorithm for free-form surface[J].Proceedings of the Institution of Mechanical Engineers,Part E:Journal of Process Mechanical Engineering,2014,228(3):197-209.
[14]ZOU Q,ZHAO J.Iso-parametric tool-path planning for point clouds[J].Computer-Aided Design,2013,45:1459-1468.
[15]CAN A,üN VAR A.A novel iso-scallop tool-path generation for efficient five-axis machining of free-form surfaces[J].AMT,2010,51(9):1083-98.
[16]徐金亭,刘伟军,卞宏友,等.基于网格曲面模型的等残留刀位轨迹生成方法[J].机械工程学报,2010,46(11):193-198.XU Jinting,LIU Weijun,BIAN Hongyou,et al.Constant scallop tool path for triangular surface machining[J].Journal of Mechanical Engineering,2010,46(11):193-198.
[17]ZOU Q,ZHANG J,DENG B,et al.Iso-level tool path planning for free-form surfaces[J].Computer-Aided Design,2014,53:117-125.
[18]王刚.自由曲面加工中基于截面线法的刀具轨迹生成研究[D].阜新:辽宁工程技术大学,2007.WANG Gang.Research on algorithm of automatic generation of interference-free tool path of freeform surfaces with curves of cross sections in the machining of the freeform surfaces[D].Fuxin:Liaoning Technical University,2007.
[19]DING S,MANNAN M,POO A N,et al.Adaptive iso-planar tool path generation for machining of free-form surfaces[J].Computer-Aided Design,2003,35(2):141-153.
[20]陈英.模具高速铣削刀具轨迹规划与工艺参数优选技术的研究[D].长春:吉林大学,2012.CHEN Ying.Research on tool path planning and process parameter optimization technology of high speed milling for die[D].Changchun:Jilin University,2012.
[21]王海春.曲面加工刀具轨迹生成技术的研究与实现[D].武汉:武汉理工大学,2009.WANG Haichun.Research and implementation for tool path generation of free form surfaces machining[D].Wuhan:Wuhan University of Technology,2009.