虚拟制造中基于刀具变形的复杂曲面加工误差预报

Machining Error Prediction of Sculptureds Surfaces Based on Spring Deflection of Ball-end Milling in Virtual Manufacturing

复杂曲面加工过程中刀具的弹性变形是产生曲面加工误差的重要原始误差。着重研究了虚拟制造环境下基于球面铣刀弹性变形的曲面加工误差预报模型。研究并建立了球面铣刀加工复杂曲面的切削力模型和刀具弹性变形模型,在此基础上,分析了曲面生成机理,提出了利用曲面变形敏感系数建立刀具弹性变形对法向加工误差的影响关系。利用该模型可以在实际切削加工前对曲面加工误差进行预报,用以进行误差补偿或切削参数优化。最后,以二维半圆形拉伸曲面为例通过切削实验对本文提出的模型进行了验证。

The spring deflection of cutting tools is an important machining error in the process of sculptured surfaces. The machining error prediction model of sculptured surfaces based on spring deflection of the ballend milling is studied so that the machining error can be predicted and analyzed before machining is carried out. On the basis of the machining error prediction model , the cutting force model and spring deflection model of the ball-end milling are analyzed and established. Based on the sculpture generation mechanism, the deflection sensitivity coefficient is proposed to establish the effect of the spring deflection of cutting tools on machining errors. These models can be employed for error compensation or cutting parameter optimization. Finally, the models are verified through the cutting tests of a 2D semicircle stretch surface.