复杂齿面的通用五轴数控机床加工技术研究
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摘要
五轴联动数控加工在复杂曲面的零件加工中具有不可替代的优势。本文将数控加工复杂曲面的方法与齿轮齿面加工相结合,提出了采用通用五轴联动机床结构,代替传统齿面加工专用机床的构想,简化了齿轮加工机床的结构,为复杂齿面的半精加工以及精加工提供了新的方法。并以常用的螺旋锥齿轮淬硬热处理后产生的微观几何变形为例,进行相关的消除齿廓形偏差的研究。
本文首先探讨了采用柱状刀具进行齿面侧刃加工时的刀位计算,分析了标准直齿齿轮副传动的啮合接触区计算方法。为了提高刀具耐用度,在刀位计算时,将切触点在刀具上的位置实现随齿面轮廓动态变化,并把刀具底刃与相邻齿廓的最小安全距离作为约束条件,得到了刀位点计算的解析解。采用UG/NX二次开发的方法,使用C语言在Visual Studio2005集成环境中进行开发刀轨udop函数的编译,将刀位点的解析解进行编译生成dll文件,并将开发的编译文件嵌入到UG/CAM加工环境中,可得到编程开发的沿轴向产生比例移动动态切触点刀轨,与UG本身CAM模块生成的刀轨相比,具有更好的灵活性。
在刀位编程计算的基础上,探讨了加工齿轮时五轴联动机床的的结构形式选择。论述了双摆头、双转台等机床结构形式,并对这些机床结构加工零件的适用范围和优缺点进行了分析,确定出本文采用双转台结构机床较为合适。
采用UG/Open API的编程方法,生成了加工齿面轮廓的试切刀轨。在选定的型号机床结构基础上,实现了UG/Post后处理器的配置及用于实际加工G代码的自动生成。并采用Vericut加工仿真软件,对生成的G代码进行了仿真几何验证。仿真结果表明,本文提出的加工刀轨生成方法,以及配置的机床结构,能够实现复杂齿面的数控加工。
5-axis linkage Numerical Control Machining have irreplaceable advantages when manufacturing sculptured surface.The paper adopted the universal5-axis linkage machine tool structure replacing the traditional special processing equipment incorporating NC Machining with gear surface machining,and provided a method for complicated tooth profile surface semifinishing and finishing.And relevant study were made about eliminating the tooth profile deviation by taking the microgeometeric distortion of helical bevel gear after the heat treatment as an example.
Firstly,the cutter location calculation of flank blade grinding finishing was discussed,and the calculation method of meshing area was analysed for standard spur gears drive.The analytical solution of cutter location point was obtained by the constraint condition of the minimum safety distance between the cutter bottom edge and adjacent tooth profile,and cutter contact point along the tooth profile changed dynamically to improve the cutter life when calculating the cutter location.The paper adopted the method of UG/NX and compiled the tool path udop function in Visual Studio2005integrated environment in C programming language,and got the compiled dll file of analytical solution.The dynamical contact point tool path was acquired to implement axial proportion variation after having embedded the dll file into the UG/CAM setting,and it was more flexible by contrast with the tool path of original UG/CAM module.
The selection of5-axis linkage machine tool was discussed for the gear's processing based on the cutter location programming.Dual-head and dual-table also other structure types were discussed,and it was analysed that of machined parts'scope of application and relative merits.The dual-table type was proper in the paper.
The testing tool path for the tooth profile surface was generated by UG/Open API programming.The UG/Post postprocessor configuration was achieved for the selected machine tool type and NC code was generated automatically for the practical NC Machining.The geometry simulation verification was achieved in Vericut machining simulation software finally.The simulation result indicates,the method of tool path generation proposed in the paper and the configurated machine tool type could achieve the NC machining of complicated tooth profile surface.
本文首先探讨了采用柱状刀具进行齿面侧刃加工时的刀位计算,分析了标准直齿齿轮副传动的啮合接触区计算方法。为了提高刀具耐用度,在刀位计算时,将切触点在刀具上的位置实现随齿面轮廓动态变化,并把刀具底刃与相邻齿廓的最小安全距离作为约束条件,得到了刀位点计算的解析解。采用UG/NX二次开发的方法,使用C语言在Visual Studio2005集成环境中进行开发刀轨udop函数的编译,将刀位点的解析解进行编译生成dll文件,并将开发的编译文件嵌入到UG/CAM加工环境中,可得到编程开发的沿轴向产生比例移动动态切触点刀轨,与UG本身CAM模块生成的刀轨相比,具有更好的灵活性。
在刀位编程计算的基础上,探讨了加工齿轮时五轴联动机床的的结构形式选择。论述了双摆头、双转台等机床结构形式,并对这些机床结构加工零件的适用范围和优缺点进行了分析,确定出本文采用双转台结构机床较为合适。
采用UG/Open API的编程方法,生成了加工齿面轮廓的试切刀轨。在选定的型号机床结构基础上,实现了UG/Post后处理器的配置及用于实际加工G代码的自动生成。并采用Vericut加工仿真软件,对生成的G代码进行了仿真几何验证。仿真结果表明,本文提出的加工刀轨生成方法,以及配置的机床结构,能够实现复杂齿面的数控加工。
5-axis linkage Numerical Control Machining have irreplaceable advantages when manufacturing sculptured surface.The paper adopted the universal5-axis linkage machine tool structure replacing the traditional special processing equipment incorporating NC Machining with gear surface machining,and provided a method for complicated tooth profile surface semifinishing and finishing.And relevant study were made about eliminating the tooth profile deviation by taking the microgeometeric distortion of helical bevel gear after the heat treatment as an example.
Firstly,the cutter location calculation of flank blade grinding finishing was discussed,and the calculation method of meshing area was analysed for standard spur gears drive.The analytical solution of cutter location point was obtained by the constraint condition of the minimum safety distance between the cutter bottom edge and adjacent tooth profile,and cutter contact point along the tooth profile changed dynamically to improve the cutter life when calculating the cutter location.The paper adopted the method of UG/NX and compiled the tool path udop function in Visual Studio2005integrated environment in C programming language,and got the compiled dll file of analytical solution.The dynamical contact point tool path was acquired to implement axial proportion variation after having embedded the dll file into the UG/CAM setting,and it was more flexible by contrast with the tool path of original UG/CAM module.
The selection of5-axis linkage machine tool was discussed for the gear's processing based on the cutter location programming.Dual-head and dual-table also other structure types were discussed,and it was analysed that of machined parts'scope of application and relative merits.The dual-table type was proper in the paper.
The testing tool path for the tooth profile surface was generated by UG/Open API programming.The UG/Post postprocessor configuration was achieved for the selected machine tool type and NC code was generated automatically for the practical NC Machining.The geometry simulation verification was achieved in Vericut machining simulation software finally.The simulation result indicates,the method of tool path generation proposed in the paper and the configurated machine tool type could achieve the NC machining of complicated tooth profile surface.
引文
[1]宁汝新,赵汝嘉,欧宗瑛.CAD/CAM技术[M].北京：机械工业出版社,1999
[2]李艳玲,李巧玲,宁振武.数控加工技术在机械制造业中的重要性[J].中国科技信息,2005,(18)：76
[3]黄卫.数控机床及故障诊断技术[M].北京：机械工业出版社,2004
[4]王志永,曾韬Phoenix Ⅱ数控螺旋锥齿轮铣齿机加工仿真[J].计算机仿真,2009,26(01)：280-283
[5]Chan IL P. Multi-objective optimization of the tooth surface in helical gears using design of experiment and the response surface method [J]. Journal of Mechanical Science and Technology, 2010,24(3):823-829
[6]李兆文,王勇,陈正洪.螺旋锥齿轮技术的研究现状[J].工具技术,2007,41(10)：3-6
[7]王志永,于水琴,曾韬.机床误差对螺旋锥齿轮齿形的影响规律[J].农业机械学报,2009,40(06)：199-202
[8]李朝光,解龙汉.UG NX5中文版多轴加工及应用实例[M].北京：清华大学出版社,2007
[9]Klocke F, Brinksmeier E, Weinert K. Capability profile of hard cutting and grinding processes[J]. CIRP Annals-Manufacturing Technology,2005,54(2):557-580
[10]杨建军,邓效忠,魏冰阳.螺旋锥齿轮超声研磨的试验研究[J].应用声学,2008,27(01)：64-68
[11]Brinksmeier E, Giwerzew A. Hard gear finishing viewed as a process of abrasive wear [J]. Wear,2005,258(1):62-69
[12]凌文锋,王小椿,姜虹.螺旋锥齿轮珩磨轮的制造方法[J].机械工程学报,2007,43(09)：138-144
[13]Lv M, Yang X. Design and manufacture of a shaving cutter with unequal depth gashes [J]. Journal of materials processing technology,2002,129 (1):193-195
[14]Karpuschewski B, Knoche H J, Hipke M. Gear finishing by abrasive processes [J]. CIRP Annals-Manufacturing Technology,2008,57(2):621-640
[15]马宁.螺旋锥齿轮脉冲电化学及电化学机械光整加工技术研究[D].[博士学位论文].大连：大连理工大学,2010
[16]殷盛福.用扩口杯砂轮磨削螺旋锥齿轮成形法大轮的过程仿真研究[D].[硕士学位论文].长沙：中南大学,2004
[17]韩旭.我国高档数控系统市场前景分析[J].中国集体经济,2008,(04)：20-21
[18]孙桓,陈作模.机械原理(第六版)[M].北京：高等教育出版社,2001
[19]周济,周艳红.数控加工技术[M].北京：国防工业出版社,2002
[20]吴继泽,王统.齿根过渡曲线与齿根应力[M].北京：国防工业出版社,1989
[21]Park D, Kahraman A. A surface wear model for hypoid gear pairs [J]. Wear,2009,267(9): 1595-1604
[22]曾韬.汽车后桥螺旋锥齿轮制造的发展方向与对策[J].世界制造技术与装备市场,2006,(06)：79-83
[23]黄翔,李迎光.UG应用开发教程与实例精解[M].北京：清华大学出版社,2005
[24]蒋玲玲,王细洋.UG二次开发的整体叶轮刀位轨迹生成[J].现代制造工程,2009,(01)：25-28
[25]动态链接库[EB]http://baike.baidu.com/view/887.htm.
[26]李群,陈五一,王瑞秋.基于UG二次开发的叶轮刀位轨迹生成[J].计算机集成制造系统,2007,13(2)：548-552
[27]张爱梅,肖燕,苏智剑,等.准双曲面齿轮的仿真加工新方法[J].机械科学与技术,2008,27(11)：1383-1386
[28]李大伟,苏智剑.格利森制弧齿锥齿轮的齿面曲率特性研究[J].机械传动,2009,33(06)：1-4
[29]王丹,徐汝锋,陈五一.基于UG二次开发的宽行加工算法实现[J].机床与液压,2008,36(12)：32-34
[30]王瑞秋.宽行数控加工理论研究及其在叶片加工中的应用[D].[博士学位论文].北京：北京航空航天大学,2007
[31]李群.微型涡轮发动机压气机整体叶轮数控加工技术的研究[D].[硕士学位论文].北京：北京航空航天大学,2006
[32]UG二次开发调试技巧[髓],http://www.cnblogs.com/begtostudy/archive/2010/11/19/1881994.html.
[33]黄翔,李迎光.数控编程理论、技术与应用[M].北京：清华大学出版社,2006
[34]蒋文兵.螺旋锥齿轮五轴联动数控加工的研究[D].[硕士学位论文].郑州：郑州大学,2003
[35]蔡兰,王霄.数控加工工艺学[M].北京：化学工业出版社,2005
[36]杨建武.国内外数控技术的发展现状与趋势[J].制造技术与机床,2008,(12)：57-62
[37]纪玉坤.基于UG的五轴数控加工NC代码仿真[D].[硕士学位论文].大连：大连理工大学,2005
[38]杨胜群,唐秀梅VERICUT数控加工仿真技术[M].北京：清华大学出版社,2010
[39]彼得.斯密德,罗学科等译FANUC数控系统用户宏程序与编程技巧[M].北京：化学工业出版社,2007
[40]王卫兵.UG NX数控编程实用教程[M].北京：清华大学出版社,2004
[41]安杰,邹昱章.UG后处理技术[M].北京：清华大学出版社,2003
[2]李艳玲,李巧玲,宁振武.数控加工技术在机械制造业中的重要性[J].中国科技信息,2005,(18)：76
[3]黄卫.数控机床及故障诊断技术[M].北京：机械工业出版社,2004
[4]王志永,曾韬Phoenix Ⅱ数控螺旋锥齿轮铣齿机加工仿真[J].计算机仿真,2009,26(01)：280-283
[5]Chan IL P. Multi-objective optimization of the tooth surface in helical gears using design of experiment and the response surface method [J]. Journal of Mechanical Science and Technology, 2010,24(3):823-829
[6]李兆文,王勇,陈正洪.螺旋锥齿轮技术的研究现状[J].工具技术,2007,41(10)：3-6
[7]王志永,于水琴,曾韬.机床误差对螺旋锥齿轮齿形的影响规律[J].农业机械学报,2009,40(06)：199-202
[8]李朝光,解龙汉.UG NX5中文版多轴加工及应用实例[M].北京：清华大学出版社,2007
[9]Klocke F, Brinksmeier E, Weinert K. Capability profile of hard cutting and grinding processes[J]. CIRP Annals-Manufacturing Technology,2005,54(2):557-580
[10]杨建军,邓效忠,魏冰阳.螺旋锥齿轮超声研磨的试验研究[J].应用声学,2008,27(01)：64-68
[11]Brinksmeier E, Giwerzew A. Hard gear finishing viewed as a process of abrasive wear [J]. Wear,2005,258(1):62-69
[12]凌文锋,王小椿,姜虹.螺旋锥齿轮珩磨轮的制造方法[J].机械工程学报,2007,43(09)：138-144
[13]Lv M, Yang X. Design and manufacture of a shaving cutter with unequal depth gashes [J]. Journal of materials processing technology,2002,129 (1):193-195
[14]Karpuschewski B, Knoche H J, Hipke M. Gear finishing by abrasive processes [J]. CIRP Annals-Manufacturing Technology,2008,57(2):621-640
[15]马宁.螺旋锥齿轮脉冲电化学及电化学机械光整加工技术研究[D].[博士学位论文].大连：大连理工大学,2010
[16]殷盛福.用扩口杯砂轮磨削螺旋锥齿轮成形法大轮的过程仿真研究[D].[硕士学位论文].长沙：中南大学,2004
[17]韩旭.我国高档数控系统市场前景分析[J].中国集体经济,2008,(04)：20-21
[18]孙桓,陈作模.机械原理(第六版)[M].北京：高等教育出版社,2001
[19]周济,周艳红.数控加工技术[M].北京：国防工业出版社,2002
[20]吴继泽,王统.齿根过渡曲线与齿根应力[M].北京：国防工业出版社,1989
[21]Park D, Kahraman A. A surface wear model for hypoid gear pairs [J]. Wear,2009,267(9): 1595-1604
[22]曾韬.汽车后桥螺旋锥齿轮制造的发展方向与对策[J].世界制造技术与装备市场,2006,(06)：79-83
[23]黄翔,李迎光.UG应用开发教程与实例精解[M].北京：清华大学出版社,2005
[24]蒋玲玲,王细洋.UG二次开发的整体叶轮刀位轨迹生成[J].现代制造工程,2009,(01)：25-28
[25]动态链接库[EB]http://baike.baidu.com/view/887.htm.
[26]李群,陈五一,王瑞秋.基于UG二次开发的叶轮刀位轨迹生成[J].计算机集成制造系统,2007,13(2)：548-552
[27]张爱梅,肖燕,苏智剑,等.准双曲面齿轮的仿真加工新方法[J].机械科学与技术,2008,27(11)：1383-1386
[28]李大伟,苏智剑.格利森制弧齿锥齿轮的齿面曲率特性研究[J].机械传动,2009,33(06)：1-4
[29]王丹,徐汝锋,陈五一.基于UG二次开发的宽行加工算法实现[J].机床与液压,2008,36(12)：32-34
[30]王瑞秋.宽行数控加工理论研究及其在叶片加工中的应用[D].[博士学位论文].北京：北京航空航天大学,2007
[31]李群.微型涡轮发动机压气机整体叶轮数控加工技术的研究[D].[硕士学位论文].北京：北京航空航天大学,2006
[32]UG二次开发调试技巧[髓],http://www.cnblogs.com/begtostudy/archive/2010/11/19/1881994.html.
[33]黄翔,李迎光.数控编程理论、技术与应用[M].北京：清华大学出版社,2006
[34]蒋文兵.螺旋锥齿轮五轴联动数控加工的研究[D].[硕士学位论文].郑州：郑州大学,2003
[35]蔡兰,王霄.数控加工工艺学[M].北京：化学工业出版社,2005
[36]杨建武.国内外数控技术的发展现状与趋势[J].制造技术与机床,2008,(12)：57-62
[37]纪玉坤.基于UG的五轴数控加工NC代码仿真[D].[硕士学位论文].大连：大连理工大学,2005
[38]杨胜群,唐秀梅VERICUT数控加工仿真技术[M].北京：清华大学出版社,2010
[39]彼得.斯密德,罗学科等译FANUC数控系统用户宏程序与编程技巧[M].北京：化学工业出版社,2007
[40]王卫兵.UG NX数控编程实用教程[M].北京：清华大学出版社,2004
[41]安杰,邹昱章.UG后处理技术[M].北京：清华大学出版社,2003