Tool Positioning Algorithm Based on Smooth Tool Paths for 5-axis Machining of Sculptured Surfaces

The current research of the 5-axis tool positioning algorithm mainly focuses on searching the local optimal tool position without gouging and interference at a cutter contact（CC） point,while not considering the smoothness and continuity of a whole tool path.When the surface curvature varies significantly,a local abrupt change of tool paths will happen.The abrupt change has a great influence on surface machining quality.In order to keep generated tool paths smooth and continuous,a five-axis tool positioning algorithm based on smooth tool paths is presented.Firstly,the inclination angle,the tilt angle and offset distance of the tool at a CC point are used as design variables,and the machining strip width is used as an objective function,an optimization model of a local tool positioning algorithm is thus established.Then,a vector equation of tool path is derived by using the above optimization model.By analyzing the equation,the main factors affecting the tool path quality are obtained.Finally,a new tool position optimization model is established,and the detailed process of tool position optimization is also given.An experiment is conducted to machine an aircraft turbine blade by using the proposed algorithm on a 5-axis blade grinding machine,and the machined blade surface is measured with a coordinate measuring machine（CMM）.Experimental and measured results show that the proposed algorithm can ensure tool paths are smooth and continuous,improve the tool path quality,avoid the local abrupt change of tool paths,and enhance machining quality and machining efficiency of sculptured surfaces.

A Generic Kinematic Model for Three Main Types of Five-axis Machine Tools

Material removal is one of the most used processes in manufacturing. Five-axis CNC machines are believed to be the best tools in sculptured surface machining. In this study, a generic and unified kinematic model was developed as a viable alternative to the particular solutions that are only applicable to individual machine configurations. This versatile model is then used to verify the feasibility of the two rotational joints within the kinematic chain of three main types of a five-axis machine-tool. This versatile model is very useful applied to the design of five-axis machine tools.

Dual Drive Curve Tool Path Planning Method for 5-axis NC Machining of Sculptured Surfaces

The problem of finished surface being not first-order continuous commonly exists in machining sculptured surfaces with a torus cutter and some other types of cutters. To solve this problem, a dual drive curve tool path planning method is proposed in this article. First, the maximum machining strip width of a whole tool path can be obtained through optimizing each tool position with multi-point machining （MPM） method. Second, two drive curves are then determined according to the obtained maximum machining strip width. Finally, the tool is positioned once more along the dual drive curve under the condition of tool path smoothness. A computer simulation and cutting experiments are carried out to testify the performance of the new method. The machined surface is measured with a coordinate measuring machine （CMM） to examine the machining quality. The results obtained show that this method can effectively eliminate sharp scallops between adjacent tool paths, keep tool paths smooth, and improve the surface machining quality as well as machining efficiency.

一种开阔自由凹曲面五坐标加工多点刀位算法

为了采用圆环面刀具加工开阔自由凹曲面,提出了一种简单快速的五坐标多点刀位算法.通过构造等距面,圆环面刀具的圆环面与理想曲面的相对关系可以等效为刀具环心圆曲线与等距面的相对关系.在等距面上构造偏置距离等于最大允许残余高度的新等距面,建立在新等距面一点处由法矢量和最小、最大主曲率方向矢量确定的局部坐标系,通过坐标变换得到空间坐标系下刀具环心圆曲线的参数方程.利用改进的求曲线曲面最小距离算法,得到不同刀位下刀具与新等距面的干涉量,当干涉量满足精度要求时停止调整刀轴,可以得到最优刀位.算例显示,新多点刀位算法不仅可以产生大的有效切削宽度,而且比以往的多点刀位算法具有更高的计算效率.

圆环面刀具五坐标数控加工旋转切触刀位算法

针对圆环面刀具加工开阔自由凹曲面,提出一种新的五坐标旋转切触刀位算法。算法来自于传统多点切触加工的逆向思考,首先确定刀具在工件曲面等距面上局部坐标系中的初始位置,然后优化调整刀具的后跟角和侧偏角,使刀具表面和工件曲面在不发生局部过切的前提下在最小主曲率方向两侧实现两点切触。与传统的多点刀位算法根据两个切触点来计算刀位不同,旋转切触刀位算法通过刀具的后跟角和侧偏角来确定最优刀位,而刀具表面和工件曲面之间的两个切触点则不需要求出。实例计算和加工仿真表明,旋转切触刀位算法不仅能够有效地产生无局部过切的多点刀位,从而不需要额外的局部过切检测及修正过程,而且在相同的加工误差下其产生的加工带宽约为UG算法的两倍,加工效率得到明显提高。

基于经线划分的非圆截面环形刀具刀位优化算法

目前环形刀具的刀位算法均未考虑圆刀片安装时存在的俯仰角和偏转角,因而在理论上存在较大的编程误差。针对实际使用刀具为非圆截面环形刀具的情况,通过对环形刀具的截面曲线进行分析,提出了一种基于经线划分的非圆截面环形刀具刀位优化算法。首先利用经线法求解出刀具表面和工件曲面之间的误差分布,然后根据此误差分布来调整刀具位置和姿态,使刀具表面与设计曲面在不发生干涉的情况下实现密切接触,从而得到刀具在指定定位点处的最优刀位。仿真结果表明,传统的五坐标刀位算法会产生较大的加工误差,而本文提出的算法消除了圆刀片安装时存在的俯仰角和偏转角所引起的加工误差,可有效提高复杂曲面的加工精度并获得满足给定编程公差的优化刀位。

复杂曲面宽行数控加工的刀位和刀具姿态综合整体优化的内蕴几何学方法

阐述了复杂曲面非球面刀具单触点宽行加工中刀位和刀具姿态综合整体优化的通用方法。基于微分几何的曲面活动标架理论,推导了以刀具曲面和设计曲面运动不变量描述非球面刀具宽行数控加工复杂曲面的刀具运动方程;在综合考虑刀位和刀具姿态的影响下,分别以一个走刀过程的加工效率和加工精度最优为目标,建立能确保刀具相对工件运动连续光滑的刀位和刀具姿态优化的泛函极值模型。最后,分别以一个鼓形曲面刀具通过旋转的主切削运动和一个椭圆抛物曲面片刀具通过直线平动的主切削运动数控加工复杂曲面的仿真实例论证了本方法的精确性、有效性和通用性。

基于包络理论的刀位误差快速求解算法

针对五坐标数控加工中刀位误差计算效率较低的问题,提出了一种基于包络原理的刀位误差快速计算方法。首先,通过描述刀位误差与最短距离线段的关系建立两者的关系式。其次,将工件曲面沿进给方向离散成若干条截型线,基于包络原理推导出工件曲面截型线到刀具曲面的距离最短点应满足的基本方程,通过求解该方程获得最短距离线段和刀位误差,建立误差分布曲线。最后,分析了W形和V形误差分布曲线的特点,对曲面截型线离散精度的确定方法进行了研究。在此基础上,设计了计算流程,开发了计算程序,算例结果表明:所提方法与原方法相比,计算效率有了很大的提高。

环面工具加工叶根过渡曲面的刀位可行域

利用环面工具加工过渡曲面时经常发生整体干涉,主要原因是缺乏对复杂环面工具加工复杂曲面时刀位可行域的研究。虽然采用常规的优化方法在大范围内对可行刀位进行搜索是可行的,但是需要耗费大量时间。为了避免刀具与过渡曲面的干涉并同时提高加工效率,研究了一种更加符合此区域结构特点的刀位优化算法,使得叶根过渡曲面得以无干涉地整体宽行加工。通过对典型叶根过渡曲面的可行刀位进行研究,发现其可行域形状为盾形,且行宽最大的刀位位于该盾形区域的两个底部边界上,有时位于该边界的端点上。根据该原理提出一种最优刀位搜索方法——沿着盾形区域底部边界搜索,应用最优化的刀位可行域以获得高的加工效率。以某航空发动机叶片的叶根过渡曲面为例进行了刀位优化计算、仿真和加工实验,验证了该方法在叶根过渡曲面加工中的有效性。