双转台五轴数控编程3D刀具半径补偿的算法研究及实现
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摘要
高速高精五轴联动数控系统及机床是一个国家的重大战略装备,也是一个强国的重要标志。它是解决大型复杂曲面例如叶轮、叶片、船用螺旋桨、重型发电机转子、汽轮机转子、大型柴油机曲轴等零件的加工的重要、甚至唯一有效手段。
然而五轴联动数控机床在实践中的应用长期以来使用起来面临两个困难或瓶颈是：一个是编制高效的数控加工程序的困难(一些著名商业软件如UG等已具有),是快速变更数控程序的困难。其根本问题之一可以归结为“3D刀具半径补偿功能的缺失”。实现3D刀具半径补偿的功能最主要的困难在于：五轴数控机床增加了两个旋转轴的运动,使得刀具空间运动,摆姿非常复杂,空间刀具半径补偿的实现变得极其困难,传统二轴、三轴刀具半径补偿已经不适合五轴3D刀具半径补偿。
针对这个问题,本文提出了五轴3D刀具半径补偿算法,并利用Visual C++6.0软件编程实现,最后在Vericut软件上进行实验仿真验证,证明它是满足要求的。文章对该领域关键问题及相关论文成果作了深入的分析、研究和总结,主要作了如下几方面的研究工作：
1.建立起3D刀具半径补偿的数学模型,推导了实现刀具半径补偿的算法。
2.以双转台机床为平台,建立机床的数学模型,推导实现后置处理的算法,并对机床运动进行求解。
3.借助UG软件对叶片模型实例进行处理,进行刀迹规划,输出刀位文件,为后面实现刀具半径补偿算法提供加工信息。
4.用Visual C++6.0开发五轴3D刀具半径补偿后置处理模拟系统,实现刀具半径补偿算法。读入刀位文件后,只需要修改相应的刀具参数,就可以输出带有补偿的刀位文件或者带有补偿的NC代码。
5.利用Vericut软件模拟加工带有补偿的NC代码。通过比较刀具半径变化后,这些实现刀具半径补偿的NC代码加工的实验结果,可以看出设计是可行的。
本文推导的算法通用性好,计算量小,只是在刀位文件信息采集时,如果刀位文件比较大时就需要大量存储空间。不过由于现代数控系统的存储的能力已经得到大大提升,所以算法能够满足加工的要求。
Five-Axis Linkage CNC System with high speed and high precision is classified as national important strategic equipment. And it is also considered as an important role, even one way, to deal with the processing of impeller, blade, marine propeller, heavy generator rotor, turbine rotor, a large diesel engine crankshaft and other complex surfaces.
However, in the practical application, Five-Axis Linkage CNC System has to face two problems:the first one is difficulty for programming; the second one is difficulty for the rapid changing NC codes. All these will conclude to the lack of3D Radius Compensation in Five-Axis CNC Linkage system, which stands up as a major bottleneck in the development of CNC system for a long time. There are some primary reasons of difficulties. Due to the two added axis of rotation, the space motion and the pose have become very complex. And the cutter radius compensation's implementation has been extremely difficult. The traditional Radius Compensation of two or three axis CNC system is not suitable for the Five-Axis CNC system.
To solve this problem, This paper puts forward the algorithm of3D Radius Compensation, applies the algorithm by using Visual C++6.0software to program and finally a validated simulation is put up in the Vericut software.The main study work and achievement are introduce in this passage as bellow based on some intensive analysis, research and summary in this field.
1. The mathematical model of3D Radius Compensation in Five-Axis CNC machining is established, by which this model can be achieved.
2. The mathematical model of Dual Rotary Table Five-Axis CNC machine is established, by which Post processing algorithm can be achieved and the movement of the Five-axis CNC machine can be solve.
3. With the help of UG software on the blade case processing, the cutter trace planning has been finished, CLS file is output to provide the processing information to derive the algorithm of3D Radius Compensation.
4. A post processing simulation system for3D Radius Compensation is developed in the Visual C++6.0platform. It has to read in CLS file, the only need is to modify the corresponding tool parameters, this system will output a new CLS file or NC codes with compensation.
5. The NC codes with compensation are simulated to process in Vericut. By comparing the experimental results of the implementation of3D Radius Compensation with different radius in the NC code processing, we can see that the design is feasible.
The algorithm derived in this paper has good universality and small amount of calculation. But it needs a lot of storage space in the information collection of cutter location file if this file is too big. However, because of the modern NC system storage capacity has been greatly improved, the algorithm can meet the processing requirements.
然而五轴联动数控机床在实践中的应用长期以来使用起来面临两个困难或瓶颈是：一个是编制高效的数控加工程序的困难(一些著名商业软件如UG等已具有),是快速变更数控程序的困难。其根本问题之一可以归结为“3D刀具半径补偿功能的缺失”。实现3D刀具半径补偿的功能最主要的困难在于：五轴数控机床增加了两个旋转轴的运动,使得刀具空间运动,摆姿非常复杂,空间刀具半径补偿的实现变得极其困难,传统二轴、三轴刀具半径补偿已经不适合五轴3D刀具半径补偿。
针对这个问题,本文提出了五轴3D刀具半径补偿算法,并利用Visual C++6.0软件编程实现,最后在Vericut软件上进行实验仿真验证,证明它是满足要求的。文章对该领域关键问题及相关论文成果作了深入的分析、研究和总结,主要作了如下几方面的研究工作：
1.建立起3D刀具半径补偿的数学模型,推导了实现刀具半径补偿的算法。
2.以双转台机床为平台,建立机床的数学模型,推导实现后置处理的算法,并对机床运动进行求解。
3.借助UG软件对叶片模型实例进行处理,进行刀迹规划,输出刀位文件,为后面实现刀具半径补偿算法提供加工信息。
4.用Visual C++6.0开发五轴3D刀具半径补偿后置处理模拟系统,实现刀具半径补偿算法。读入刀位文件后,只需要修改相应的刀具参数,就可以输出带有补偿的刀位文件或者带有补偿的NC代码。
5.利用Vericut软件模拟加工带有补偿的NC代码。通过比较刀具半径变化后,这些实现刀具半径补偿的NC代码加工的实验结果,可以看出设计是可行的。
本文推导的算法通用性好,计算量小,只是在刀位文件信息采集时,如果刀位文件比较大时就需要大量存储空间。不过由于现代数控系统的存储的能力已经得到大大提升,所以算法能够满足加工的要求。
Five-Axis Linkage CNC System with high speed and high precision is classified as national important strategic equipment. And it is also considered as an important role, even one way, to deal with the processing of impeller, blade, marine propeller, heavy generator rotor, turbine rotor, a large diesel engine crankshaft and other complex surfaces.
However, in the practical application, Five-Axis Linkage CNC System has to face two problems:the first one is difficulty for programming; the second one is difficulty for the rapid changing NC codes. All these will conclude to the lack of3D Radius Compensation in Five-Axis CNC Linkage system, which stands up as a major bottleneck in the development of CNC system for a long time. There are some primary reasons of difficulties. Due to the two added axis of rotation, the space motion and the pose have become very complex. And the cutter radius compensation's implementation has been extremely difficult. The traditional Radius Compensation of two or three axis CNC system is not suitable for the Five-Axis CNC system.
To solve this problem, This paper puts forward the algorithm of3D Radius Compensation, applies the algorithm by using Visual C++6.0software to program and finally a validated simulation is put up in the Vericut software.The main study work and achievement are introduce in this passage as bellow based on some intensive analysis, research and summary in this field.
1. The mathematical model of3D Radius Compensation in Five-Axis CNC machining is established, by which this model can be achieved.
2. The mathematical model of Dual Rotary Table Five-Axis CNC machine is established, by which Post processing algorithm can be achieved and the movement of the Five-axis CNC machine can be solve.
3. With the help of UG software on the blade case processing, the cutter trace planning has been finished, CLS file is output to provide the processing information to derive the algorithm of3D Radius Compensation.
4. A post processing simulation system for3D Radius Compensation is developed in the Visual C++6.0platform. It has to read in CLS file, the only need is to modify the corresponding tool parameters, this system will output a new CLS file or NC codes with compensation.
5. The NC codes with compensation are simulated to process in Vericut. By comparing the experimental results of the implementation of3D Radius Compensation with different radius in the NC code processing, we can see that the design is feasible.
The algorithm derived in this paper has good universality and small amount of calculation. But it needs a lot of storage space in the information collection of cutter location file if this file is too big. However, because of the modern NC system storage capacity has been greatly improved, the algorithm can meet the processing requirements.
引文
[1]廖效果,刘又午,朱剑英.数控技术[M].武汉湖北科学技术出版社,2005.5：1-2.
[2]王永章,杜君文,程国全.数控技术[M].高等教育出版社,2001：1O-20.
[3]章富元,方江龙,汤季安.对我国数控技术发展的思考[J].中国机械工程.1999(10)：1100-1103.
[4]Dragomatz D Mann S.A Classified Bibliography of Literuatreon NC Milling Path Generation[J]. Computer Aided Design.2002,29(3):239-247.
[5]M.Kovacic, M.Brezocnik, I.Pahole. Evolutionary programming of CNC machines[J]. Journal of Materials Processing TechnologY,2005:1379-1387.
[6]陈明君,李凯,李子昂.五轴数控刀具半径补偿算法研究与数控仿真[J].工具技术,2010,44(3).
[7]M. Kovacic, M. Brezocnik, I. Pahole, J. Balic, B. Kecelj. Evolutionary programming of CNC machines[J]. Journal of Materials Processing Technology,164-165 (2005): 1379-1387.
[8]Y.Y. Hsu, S.S. Wang. A new compensation method for geometry errors of five-axis machine tools[J]. International Journal of Machine Tools & Manufacture 47 (2007): 352-360.
[9]姜博.欧洲B数控企业面向中国市场竞争策略研究[J].中国人民大学,2009.
[10]郭自娟.五轴数控系统刀具半径补偿的研究[D].中国科学院沈阳计算机研究所,2010.
[11]http://www.c-cnc.com/news/newsfile/2012/1/18/946551.shtml.
[12]中国机床工具工业协会市场部.CIMT精品荟萃[J],世界制造技术与装备市场,2007(2)：84-92.
[13]李东茹.我国数控技术发展与展望[J].世界制造技术与装备市场,2006(1)：30-35.
[14]中国机床工具工业协会数控系统分会.从CCMT2008看数控系统发展趋势及国内发展水平[J].机械工程师.2008年第8期.
[15]陈良骥,王永章.五轴联动数控加工中的刀具补偿方法[J].制造技术与机床,2006(2)：22-25.
[16]刘德福,陈峰.计算机数控系统三维刀具半径补偿研究[J].组合机床与自动化加工技术,2001(8)：9-11.
[17]胡自化,张平,杨冬香,等.三轴数控侧铣空间刀具半径补偿算法[J].机械工程学报,2007,44(5)：139-142.
[18]卜建荣.基于五轴数控加工中环形刀具的成形技术研究[D].浙江工业大学,2009.
[19]刘雄伟等.数控加工理论与编程技术[M].北京：机械工业出版社,2001：10-17.
[20]唐建明,卞进泽.西门子840D五轴联动刀具补偿及应用[J].机械工人,2004(12)：62-64.
[21]丁叔.5轴数控曲面加工原理及编程[J].计算机辅助设计与制造,1995(9)：42-43.
[22]Dao Yuanyu, Jian Chundeng, Zheng Chengduan, et al. Generation of gouge-free cutter location paths on free form surface for non-pherical[J]. Computer in Industry,1996, 28(2):81-94.
[23]袁哲俊,王先奎.精密和超精密加工技术[M].北京：机械工业出版社,1999：1-15.
[24]洪海涛,于东等.五轴端铣加工中3D刀具半径补偿研究[J].中国机械工程,2009,20(15).
[25]Ai fen Xu,Tai yong Wang. Study on the Technology of 3D Cutter Radius Compensation Based on Direction Vector [J]. Proceedings of the 2010 IEEE,2010:1190-1194.
[26]冯显英,葛荣雨.五坐标数控机床后置处理算法的研究[J].工具技术,2006(40)：44-46.
[27]蔡永林,席光,查建中.五坐标数控加工后置处理算法的研究[J].组合机床与自动化技术,2003(9)：17-20.
[28]畲振华,陈正堂.多轴加工数控程序刀具补偿算法研究[J].(台)大叶大学,文章来源：hotmold.com.
[29]Wang Gang, Xun Jingbin, Wang Taiyong, Zhang Zhiqiang. The development of Tool Compensation software for 5-axis CNC system[J].2010 International Conference on Digital Manufacturing & Automation,6664-6667.
[30]E.L.GBohez. Compensating for systematic errors in 5-axis NC machine. Computer-Aided Design:34(2002):391-403.
[31]Shaowei Zhu, Guofu Ding, Shengfeng Qin, Jiang Lei, Li Zhuang, Kaiyin Yan. Integrated geometric error modeling,identification and compensation of CNC machine tools[J]. International Journal of Machine Tools & Manufacture:52 (2012) 24-29.
[32]任军学,刘维伟,汪文虎,孟晓娴.五坐标数控机床后置处理算法[J].航空计算技术.2000,30(1)：41-43.
[33]刘雄伟,王增强,杨海成.五坐标数控加工后置处理[J].组合机床与自动化加工技术.1994(1)：7-10.
[34](韩)Kunwoo Lee. CAD/CAM/CAE系统原理[M].袁清珂,张湘伟等,译.北京：电子工业出版社,2006：41-44.
[35]高长银,臧稳通,赵汶等.UG NX6.0数控五轴加工实例教程[M].北京：化学工业出版社,2009.8：30-44.
[36]温正,魏建中.精通UG NX6.0数控加工[M].北京：科学出版社,2009：432-433.
[37]S. M. Wang, K.F.Ehmann. Measurement Method for Position Error of a Multiaxis Machine-Partll Applications and Experimental Results[J]. International Journal of Machine Tools and Manuafcutring.1999, (4):1485-1505.
[38]杨乐.五轴联动数控系统刀具半径补偿[D].哈尔滨工业大学,2006.
[39]任学军,刘维伟,汪文虎.五坐标数控机床后置处理算法[J].航空计算技术.2000：40-43.
[40]杨胜群,唐秀梅等.VERICUT数控加工仿真技术[M].北京：清华大学出版社.2010.4.
[41]郑贞平,黄云林,黎胜容. VERICUT7.0中文版数控仿真技术与应用实例详解[M].北京：机械工业出版社.2011.4.
[2]王永章,杜君文,程国全.数控技术[M].高等教育出版社,2001：1O-20.
[3]章富元,方江龙,汤季安.对我国数控技术发展的思考[J].中国机械工程.1999(10)：1100-1103.
[4]Dragomatz D Mann S.A Classified Bibliography of Literuatreon NC Milling Path Generation[J]. Computer Aided Design.2002,29(3):239-247.
[5]M.Kovacic, M.Brezocnik, I.Pahole. Evolutionary programming of CNC machines[J]. Journal of Materials Processing TechnologY,2005:1379-1387.
[6]陈明君,李凯,李子昂.五轴数控刀具半径补偿算法研究与数控仿真[J].工具技术,2010,44(3).
[7]M. Kovacic, M. Brezocnik, I. Pahole, J. Balic, B. Kecelj. Evolutionary programming of CNC machines[J]. Journal of Materials Processing Technology,164-165 (2005): 1379-1387.
[8]Y.Y. Hsu, S.S. Wang. A new compensation method for geometry errors of five-axis machine tools[J]. International Journal of Machine Tools & Manufacture 47 (2007): 352-360.
[9]姜博.欧洲B数控企业面向中国市场竞争策略研究[J].中国人民大学,2009.
[10]郭自娟.五轴数控系统刀具半径补偿的研究[D].中国科学院沈阳计算机研究所,2010.
[11]http://www.c-cnc.com/news/newsfile/2012/1/18/946551.shtml.
[12]中国机床工具工业协会市场部.CIMT精品荟萃[J],世界制造技术与装备市场,2007(2)：84-92.
[13]李东茹.我国数控技术发展与展望[J].世界制造技术与装备市场,2006(1)：30-35.
[14]中国机床工具工业协会数控系统分会.从CCMT2008看数控系统发展趋势及国内发展水平[J].机械工程师.2008年第8期.
[15]陈良骥,王永章.五轴联动数控加工中的刀具补偿方法[J].制造技术与机床,2006(2)：22-25.
[16]刘德福,陈峰.计算机数控系统三维刀具半径补偿研究[J].组合机床与自动化加工技术,2001(8)：9-11.
[17]胡自化,张平,杨冬香,等.三轴数控侧铣空间刀具半径补偿算法[J].机械工程学报,2007,44(5)：139-142.
[18]卜建荣.基于五轴数控加工中环形刀具的成形技术研究[D].浙江工业大学,2009.
[19]刘雄伟等.数控加工理论与编程技术[M].北京：机械工业出版社,2001：10-17.
[20]唐建明,卞进泽.西门子840D五轴联动刀具补偿及应用[J].机械工人,2004(12)：62-64.
[21]丁叔.5轴数控曲面加工原理及编程[J].计算机辅助设计与制造,1995(9)：42-43.
[22]Dao Yuanyu, Jian Chundeng, Zheng Chengduan, et al. Generation of gouge-free cutter location paths on free form surface for non-pherical[J]. Computer in Industry,1996, 28(2):81-94.
[23]袁哲俊,王先奎.精密和超精密加工技术[M].北京：机械工业出版社,1999：1-15.
[24]洪海涛,于东等.五轴端铣加工中3D刀具半径补偿研究[J].中国机械工程,2009,20(15).
[25]Ai fen Xu,Tai yong Wang. Study on the Technology of 3D Cutter Radius Compensation Based on Direction Vector [J]. Proceedings of the 2010 IEEE,2010:1190-1194.
[26]冯显英,葛荣雨.五坐标数控机床后置处理算法的研究[J].工具技术,2006(40)：44-46.
[27]蔡永林,席光,查建中.五坐标数控加工后置处理算法的研究[J].组合机床与自动化技术,2003(9)：17-20.
[28]畲振华,陈正堂.多轴加工数控程序刀具补偿算法研究[J].(台)大叶大学,文章来源：hotmold.com.
[29]Wang Gang, Xun Jingbin, Wang Taiyong, Zhang Zhiqiang. The development of Tool Compensation software for 5-axis CNC system[J].2010 International Conference on Digital Manufacturing & Automation,6664-6667.
[30]E.L.GBohez. Compensating for systematic errors in 5-axis NC machine. Computer-Aided Design:34(2002):391-403.
[31]Shaowei Zhu, Guofu Ding, Shengfeng Qin, Jiang Lei, Li Zhuang, Kaiyin Yan. Integrated geometric error modeling,identification and compensation of CNC machine tools[J]. International Journal of Machine Tools & Manufacture:52 (2012) 24-29.
[32]任军学,刘维伟,汪文虎,孟晓娴.五坐标数控机床后置处理算法[J].航空计算技术.2000,30(1)：41-43.
[33]刘雄伟,王增强,杨海成.五坐标数控加工后置处理[J].组合机床与自动化加工技术.1994(1)：7-10.
[34](韩)Kunwoo Lee. CAD/CAM/CAE系统原理[M].袁清珂,张湘伟等,译.北京：电子工业出版社,2006：41-44.
[35]高长银,臧稳通,赵汶等.UG NX6.0数控五轴加工实例教程[M].北京：化学工业出版社,2009.8：30-44.
[36]温正,魏建中.精通UG NX6.0数控加工[M].北京：科学出版社,2009：432-433.
[37]S. M. Wang, K.F.Ehmann. Measurement Method for Position Error of a Multiaxis Machine-Partll Applications and Experimental Results[J]. International Journal of Machine Tools and Manuafcutring.1999, (4):1485-1505.
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