铝合金整体叶轮数控铣削加工研究

CNC Milling Research of Aluminum Alloy Integrated Impeller

针对铝合金整体叶轮五轴数控高速加工存在的主要问题进行了较为系统的研究。首先,建立了铣削力模型,通过铣削实验求解出切削力系数,并验证了模型的准确性;其次,通过锤击法对叶轮叶片模态进行了实量,得出了在不同加工状态下叶片的模态变化情况;再次,基于铣削力系数和模态实验结果,依据铣削动力学模型,研究了高速铣削的稳定性问题,分析了极限轴向切削深度与主轴转速之间的关系,绘制了高速铣削稳定性极限图;最后,优化了刀轴姿态和轨迹,在此基础上对叶轮叶片型面性能参数进行了快速检测。应用上述研究成果,某运载装备发动机铝合金叶轮加工效率提高了35%,叶片型面测量效率提高了10倍,叶片表面完全消除了过切、振痕和大波纹,质量显著提高。

In this paper,the main problems of aluminum alloy integrated impeller 5-axis CNC high speed machining are studied systematically. First of all,the milling force model is established,the cutting force coefficients are solved through milling experiments,and the accuracy of the model is verified. Second,the hammering method is used to obtain modal changes of the blade in different processing conditions. Then,based on the milling force coefficients and modal experimental results,high-speed milling stability is researched according to the milling dynamics model. The relationship between the limit axial depth of cut and spindle speed is analyzed and a high-speed milling stability limit diagram is drawn. Finally,the tool posture and path are optimized and on the basis of this the rapid detection of the impeller blade surface performance parameters are carried. Application of the above research results,the processing efficiency of one type carrying engine of aluminum alloy integrated impeller is improved by 35%,the blade surface measurement efficiency is improved by 10 times,and both the over-cut,chatter marks and external waviness on the blade surface are completely eliminate,besides,the quality has improved significantly to meet the requirements of the scene.