钛合金型腔插铣刀具轨迹优化方法研究
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摘要
钛合金材料的切削性能较差,如何提高切削效率成为研究重点。插铣方法因其独特的走刀方式和切削特点,在钛合金的型腔加工过程中可以很好的金属切屑去除率进行切削加工,受到普遍的关注和研究。本文针对插铣加工Z向切削的特点,对插铣刀具轨迹生成方法进行研究,并基于对填充圆网格划分的改进,提出综合环切特点的型腔插铣加工刀具轨迹的改进填充圆法生成策略,实现了插铣加工的高效快速切削。主要研究内容如下:
1.基于二维型腔的结构以及插铣加工走刀方式的特点,针对对填充圆刀位点生成的覆盖区域不充分的缺陷,提出网格增补改进方法,并基于此对插铣刀具轨迹规划进行研究,提出插铣刀具轨迹生成的填充圆网格法。
2.系统研究插铣刀具轨迹生成的过程和方法,提出参考刀具轨迹的概念,即刀位点的初始连接顺序。利用遗传算法对参考刀具轨迹进行优化,针对刀位点产生后的间距偏大的问题,采用刀位点插值,改善刀具的径向切削宽度。
3.结合环切法刀具轨迹生成的特点,提出一种插铣刀具轨迹的实用性调整方法,该方法可以有效避免在切削过程中由于走刀方向改变造成的加工余量不均匀。
4.研究插铣加工工艺过程,总结刀具和切削用量的选择规则及知识,提出根据型腔几何形状交互选择多刀具的方法。
5.在上述研究的基础上,开发基于填充圆网格方法的插铣加工刀具轨迹生成及优化软件功能模块,并结合具体实例,阐述软件运行过程,验证所提出方法的正确性和可行性。
In recent years, how to improve the cutting efficiency becomes the key problem for Titanium alloy parts processing operation because of whose poor machinability. Plunge milling plays an important role in Titanium alloy machining because it has good chip metal removal rate with a unique type of movement, and is extensively studied. In this thesis, tool path generation methods are studied considering the characteristics of Z-direction cutting; a novel strategy of tool path generation integrating with contour-parallel method is proposed based on Ocfill (Overlapped Circle Filling) method and its improvements; so that high-efficient and fast cutting of plunge milling for Titanium alloy can be realized. The main contents are as follows:
1. Based on the structure of the cavity and the movement type of plunging, enhancing method is putted forward for the defection of the Ocfill grid to get more reasonable cutter sites. With the result, path generation method with Ocfill gird is studied.
2. The process of path generation is studied and the concept of reference path, witch is the original trail of the cutter, is used and optimalized with Generic Algorithm. The depth of the cutter in radial direction is modified with inserting tool sites.
3. To get good result, an adaptable method is put forward witch is based on the way of boundary-parallel machining. In this method, the uniformity of left material is modified.
4. The technics of plunge processing is studied. The principles and knowledge of cutter selection and cutting parameters are summarized. The minimum tool is to be selection according to the pocket geometry and the series of larger tools are chosen based on this one.
5. On the basis of abovementioned theories and methods, the CAM software of plunge milling with Ocfill grid method to generate cutter path is developed, and its feasibility is illustrated with examples.
1.基于二维型腔的结构以及插铣加工走刀方式的特点,针对对填充圆刀位点生成的覆盖区域不充分的缺陷,提出网格增补改进方法,并基于此对插铣刀具轨迹规划进行研究,提出插铣刀具轨迹生成的填充圆网格法。
2.系统研究插铣刀具轨迹生成的过程和方法,提出参考刀具轨迹的概念,即刀位点的初始连接顺序。利用遗传算法对参考刀具轨迹进行优化,针对刀位点产生后的间距偏大的问题,采用刀位点插值,改善刀具的径向切削宽度。
3.结合环切法刀具轨迹生成的特点,提出一种插铣刀具轨迹的实用性调整方法,该方法可以有效避免在切削过程中由于走刀方向改变造成的加工余量不均匀。
4.研究插铣加工工艺过程,总结刀具和切削用量的选择规则及知识,提出根据型腔几何形状交互选择多刀具的方法。
5.在上述研究的基础上,开发基于填充圆网格方法的插铣加工刀具轨迹生成及优化软件功能模块,并结合具体实例,阐述软件运行过程,验证所提出方法的正确性和可行性。
In recent years, how to improve the cutting efficiency becomes the key problem for Titanium alloy parts processing operation because of whose poor machinability. Plunge milling plays an important role in Titanium alloy machining because it has good chip metal removal rate with a unique type of movement, and is extensively studied. In this thesis, tool path generation methods are studied considering the characteristics of Z-direction cutting; a novel strategy of tool path generation integrating with contour-parallel method is proposed based on Ocfill (Overlapped Circle Filling) method and its improvements; so that high-efficient and fast cutting of plunge milling for Titanium alloy can be realized. The main contents are as follows:
1. Based on the structure of the cavity and the movement type of plunging, enhancing method is putted forward for the defection of the Ocfill grid to get more reasonable cutter sites. With the result, path generation method with Ocfill gird is studied.
2. The process of path generation is studied and the concept of reference path, witch is the original trail of the cutter, is used and optimalized with Generic Algorithm. The depth of the cutter in radial direction is modified with inserting tool sites.
3. To get good result, an adaptable method is put forward witch is based on the way of boundary-parallel machining. In this method, the uniformity of left material is modified.
4. The technics of plunge processing is studied. The principles and knowledge of cutter selection and cutting parameters are summarized. The minimum tool is to be selection according to the pocket geometry and the series of larger tools are chosen based on this one.
5. On the basis of abovementioned theories and methods, the CAM software of plunge milling with Ocfill grid method to generate cutter path is developed, and its feasibility is illustrated with examples.
引文
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[3] Shunsuke Wakkoka, Yasuo Yamane, Katsuhiko Sekiya, Norihiko Naruki, High-speed and High-accuracy plunge cutting for vertical walls, Journal of Materials Processing Technology, 2002,127: 246-250.
[4]李树侠,朴松花,钛合金材料的机械加工工艺综述.飞航导弹, 2007, 7: 57-61
[5] Jeong Hook Ko, Yusuf Altinas, Time domain model of plunge milling operation, International Journal of Machine Tool & Manufacture, 2007, 47: 1351-1361
[6] Hirano .c,Morishiqe .K,Development of rough cutting method with plunge milling using 5-axis control machine tool,Journal of the Japan Society of Precision Engineering, 2007-11, 73(11): 1261-1266.
[7] Rauch .M, Rough pocket milling with trochoidal and plunging strategies, International Journal of Machining and Mach inability of Materials, 2007, 2(2): 161-175.
[8] Thomas Semon Stelson, Stephen Curtis Jerrome, Rebort Albin Meditz, Contour Plunge Milling, US, Field of Search, Patent Number(s): US 6,929,425 B2, Date of Patent: Aug.16, 2005
[9]郭连水,刘秋丰,曹浩波.涡轮叶盘数控加工优化方法的研究与实现,新技术新工艺, 2005, 2: 19-21
[10]胡创国,张定华,任军学等.开式整体叶盘通道插铣粗加工技术的研究,中国机械工程.2007,18(2): 153-155
[11]王增强,单晨伟,任军学等.开式整体叶盘四坐标插铣开槽粗加工刀位轨迹规划,航空制造技术, 2007, 2: 94-97
[12]王庭俊.基于插铣法和宏程序的矩形腔铣削,煤矿机械, 2006, 27(12): 106-108
[13]齐文国,孙建军,赵剑波等.铝合金插铣铣削力建模与分析,组合机床与自动化加工技术, 2007, 1: 32-40
[14]秦旭达,赵剑波,张剑刚等.基于回归法的钛合金(Ti-6Al-4V)插铣铣削力建模分析,北京工业大学学报, 2006, 8: 737-740
[15]安鲁陵,周来水,庄海军等,型腔高速铣削刀轨生成算法研究.计算机辅助设计与图形学学报, 2004, 16(9): 1202-1206
[16]赵元伟,周雄辉等,多区域行切加工路径优化.模具技术, 2004-9, 6(14): 14-16
[17]方向,彭群生,郑家骧, 2.5轴复杂型腔的刀位轨迹生成算法,工程图学学报, 2000, 1:19-27
[18]俞武嘉,傅建中,陈子辰,基于遗传算法的刀具路径优化排布方法,浙江大学学报(工学版), 2006, 40(12): 2118-2121
[19]胡俊志,黄翔,李迎光,型腔转角插铣粗加工方法.机械制造与研究, 2008-7, 37(3): 37-39
[20] Stephen P. Radizevich, A closed-form solution to the problem of optimal tool-path generation for sculptured surface machining on multi-axis NC machine, Mathematical and Computer Modeling , 2006, 43: 222-243
[21]滕飞,闫光荣,简斌,采用增量优化原理的刀具轨迹优化算法研究,工程图学学报, 2007
[22]江开勇,林俊义,平面型腔平行双向刀具轨迹的优化生成,制造业自动化, 2005, 27(6): 28-30
[23] Tawfik T.El-Midany, Ahmed Elkeran, Hamdy Tawfik, Optimal CNC Plunger Selection and Tool point Generation for Roughing Sculptured Surfaces Cavity, Journal of Manufacturing Science and Engineering, 2006, 128(4): 1025-1029
[24]张云静,李红运,姚凌云. UG NX 5.0中文版数控加工,北京:电子工业出版社, 2008. 2
[25]唐国良. Cimatron系列-CimatronCAD/CAM范例入门,北京:北京大学出版社, 2003: 1-2
[26]李腾. Pro/ENGINEERING野火版3.0自学手册—入门提高篇,北京:人民邮电出版社, 2007: 2-3
[27] CAXA产品介绍, http://www.fjmie.org.cn/Page/szhsj/2006-7/30/2101366269.ht ml, (2004)
[28]胡仁喜,刘昌丽,张乐乐, CAXA电子图板应用教程,北京:清华大学出版社, 2007
[29] WorkNC的使用经验, http://bbs.nuguo.com/p16134p1p1, (2009).
[30]许丽佳,蒲海波,蒋宏健.改进遗传算法的路径规划研究,微机算机信息, 2006, 22(2-2): 251-253
[31]李艳萍,张挺,一种求解TSP问题的新型遗传算法.太原理工大学学报, 2008, 39(3): 268-271
[32]唐立山, CAM后置处理研究.机械工程师, 2005(7):57-58
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