整体叶盘球头鼓锥形铣刀五轴加工技术

Five Axis Machining Technology of Barrel Taper Ball Milling Cutter of Blisk

鼓形铣刀作为一种高效率的复杂曲面加工刀具,属于非标刀具范畴,其几何参数需要根据加工条件专门定制,目前,定制鼓形铣刀几何参数的有效工具的缺乏是限制其推广应用的主要问题。针对整体叶盘五轴数控加工,提出一种球头鼓锥形铣刀定制方法。该方法通过综合考虑防止干涉的侧倾角、清根加工的球头半径、保证效率的切削行距等约束条件,建立了刀具外轮廓数学模型,编写了刀具参数自动生成的程序。三叶片试件加工仿真和实际切削的结果表明,球头鼓锥形铣刀可以在不降低刀具刚度的条件下,满足叶盘试件加工。与球头铣刀加工相比,其加工效率能够成倍提升,叶片表面质量也有显著提高。

Barreol milling cutter,as a kind of highly efficient tool for machining complex curved surface,belongs to non-standard cutting tools.Its geometric parameters need to custom-made according to the processing conditions.The lack of effective tools for customizing barrel milling cutter geometrical parameters is one of the major problems of restricting the popularization and application.Aiming at the five axis NC machining of blisk,a method of customizing barrel-taper ball milling cutter is put forward.In this method,the mathematical model of the outer contour of the tool is established and the program of automatic generation of the tool parameters is compiled by comprehensively considering the constraints such as the roll angle to prevent interference,radius of the ball head of clean-up machining and the cutting row spacing to ensure the efficiency.The results of machining simulation and actual cutting of three blade specimens show that the barrel taper ball milling cutter can meet the processing of the blisk without reducing the tool stiffness.Compared with the ball milling cutter,the machining efficiency can improves exponentially and the surface quality of blade improves significantly.