一种拉刀螺旋容屑槽前刀面磨削砂轮安装位姿计算方法

An Approach on Wheel Setup Calculation for Helical Rake Flank Sharpening of Broaching Tool

螺旋容屑槽是螺旋拉刀的重要结构之一,螺旋前刀面的高质量精确磨削对于刀具的工作性能与服役寿命有着重要影响。提出了一种适用于螺旋前刀面刃磨的砂轮安装位姿计算方法,确保螺旋前刀面的精密磨削。首先从五轴加工角度构建砂轮安装位姿与磨削运动数学模型,然后基于离散砂轮空间运动扫掠体进行螺旋槽轴截面加工廓形的离散包络计算,并给出相应的离散磨削接触线追溯算法。在此基础上,进一步分析拉刀前刀面的磨削工艺并构建磨削工艺约束条件,形成拉刀螺旋前刀面刃磨的砂轮安装位姿计算模型及其优化搜索方法。最后进行了实例求解,通过与解析法计算结果的精度对比和磨削接触线分布位置的状态验证了该算法的有效性,并进一步对砂轮安装角、砂轮外径和加工槽宽的关系进行讨论,给出了实际应用中的砂轮安装位姿优选规则。

Helical gullets are important structure of the helical broaching tools,and the precision and high-quality sharpening for the corresponding rake flanks is significant to the work performance and the life of the broaching tools.Therefore,a wheel setup method for the helical rake flank sharpening is proposed.Firstly,the wheel setup model and the motion matrix are established.Next,a discrete spatial wheel swept volume based machined gullet axial section profile identification method is presented,as well as the tracing of the discrete contact curve.On this foundation,the grinding processes of helical rake flank are analyzed and the constraints conditions are summarized,the wheel orientation calculation model for the helical rake flank is given as well as the optimized search solving method.At last,examples are performed by proposed method,and its effectiveness is verified by the precision comparison with analytical method results and the distribution status of contact curve.Moreover,the analyses of the relationship among wheel orientation,wheel radius and width of machined gullet is taken,and optimal selection of wheel setup is suggested.