车刀TPU保护套的正逆向混合设计与增材制造

Forward and Reverse Hybrid Design and Additive Manufacturing of TPU Protective Sleeves for Turning Tools

正逆向混合设计、增材制造技术分别是开发、制造产品原型的快捷方式。以PROXXON精密车床用1HSS/Co5型车刀保护套为设计对象,采用热塑性聚氨酯(TPU)柔性材料,通过逆向设计到正向设计再到增材制造的产品开发流程,设计并制造出既贴合车刀曲面外形、又具有良好缓冲防护性能的车刀TPU保护套。结果表明,经点云处理后,车刀扫描点的数量减少了58%,达到了明显精简的效果;经面片处理后,车刀三角面片的数量减少了45%,达到了明显光顺的效果;车刀逆向重构模型的误差范围为±0.2 mm,相对于实物原型的拟合度较高;碰撞仿真分析结果显示,安装有保护套的车刀比没有安装保护套的车刀的最大应力值下降了98.46%,说明车刀TPU保护套具有良好的缓冲防护性能。基于正逆向混合设计与增材制造技术的车刀TPU保护套有效保护了车刀的刀头结构,降低了储存、搬运和取用的过程中车刀损坏的风险,同时避免了车刀对操作人员的碰触伤害,为同类定制保护套的快速开发提供参考。

Forward and reverse hybrid design and additive manufacturing technology are shortcuts for developing and manufacturing product prototypes,respectively.Taking the 1HSS/Co5 type turning tool protection sleeve used in PROXXON precision lathe as the design object,and adopting the product development process from reverse design to forward design and then to additive manufacturing,through thermoplastic polyurethane(TPU)flexible material,a turning tool TPU protective sleeve was designed and manufactured that not only fitted the curved surface shape of the turning tool,but also had good cushioning and protection performance.The results show that after point cloud processing,the number of scanning points for turning tools is reduced by 58%,achieving a significant simplification effect.After surface treatment,the number of triangular surfaces on the turning tool is reduced by 45%,achieving a significant smoothing effect.The error range of the reverse reconstruction model for turning tools is±0.2 mm,which has a higher fitting degree compared to the physical prototype.The collision simulation analysis results show that the maximum stress value of turning tools with protective sleeves decreases by 98.46%compared to those without protective sleeves,indicating that the TPU protective sleeve for turning tools has good buffering and protection performance.The TPU protective sleeve for turning tools based on forward and reverse hybrid design and additive manufacturing technology effectively protects the blade structure of the turning tool,reduces the risk of damage to the turning tool during storage,handling and retrieval,and avoids contact injuries to operators by the turning tool.This provides a reference for the rapid development of similar customized protective sleeves.