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New Mathematical Method for the Determination of Cutter Runout Parameters in Flat-end Milling 被引量:2
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作者 GUO Qiang SUN Yuwen +1 位作者 GUO Dongming ZHANG Chuantai 《Chinese Journal of Mechanical Engineering》 SCIE EI CAS CSCD 2012年第5期947-952,共6页
The cutting force prediction is essential to optimize the process parameters of machining such as feed rate optimization, etc. Due to the significant influences of the runout effect on cutting force variation in milli... The cutting force prediction is essential to optimize the process parameters of machining such as feed rate optimization, etc. Due to the significant influences of the runout effect on cutting force variation in milling process, it is necessary to incorporate the cutter runout parameters into the prediction model of cutting forces. However, the determination of cutter runout parameters is still a challenge task until now. In this paper, cutting process geometry models, such as uncut chip thickness and pitch angle, are established based on the true trajectory of the cutting edge considering the cutter runout effect. A new algorithm is then presented to compute the cutter runout parameters for flat-end mill utilizing the sampled data of cutting forces and derived process geometry parameters. Further, three-axis and five-axis milling experiments were conducted on a machining centre, and resulting cutting forces were sampled by a three-component dynamometer. After computing the corresponding cutter runout parameters, cutter forces are simulated embracing the cutter runout parameters obtained from the proposed algorithm. The predicted cutting forces show good agreements with the sampled data both in magnitude and shape, which validates the feasibility and effectivity of the proposed new algorithm of determining cutter runout parameters and the new way to accurately predict cutting forces. The proposed method for computing the cutter runout parameters provides the significant references for the cutting force prediction in the cutting process. 展开更多
关键词 flat end milling cutter runout cutting force five-axis machining
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Analytical modeling of geometric errors induced by cutter runout and tool path optimization for five-axis flank machining 被引量:7
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作者 GUO Qiang SUN YuWen GUO DongMing 《Science China(Technological Sciences)》 SCIE EI CAS 2011年第12期3180-3190,共11页
The cutter runout effect has significant influence on the shape of cutter swept surface and the machining surface quality. Hence,it is necessary to integrate the cutter runout effect in cutter swept surface modeling,g... The cutter runout effect has significant influence on the shape of cutter swept surface and the machining surface quality. Hence,it is necessary to integrate the cutter runout effect in cutter swept surface modeling,geometric error prediction and tool path optimization for five-axis flank machining. In this paper,an envelope surface model considering cutter runout effect is first established,and geometric errors induced by runout effect are derived based on the relative motion analysis between the cutter and part in machining. In the model,the cutter runout is defined by four parameters,including inclination angle,location angle,offset value and the length of cutter axis. Then the runout parameters are integrated into the rotation surface of each cutting edge that is used to form the final cutter envelope surface for the five-axis machining process. Thus,the final resulting geometric errors of the machined surface induced by cutter runout can be obtained through computing the deviations from the nominal cutter swept surface. To reduce these errors,an iterative least square method is used to optimize the tool paths for five-axis flank machining. Finally,a validation example is given for a specific ruled surface. Results show the effectiveness and feasibility of the analytical model of geometric errors induced by cutter runout,and also show that the geometric errors can be reduced significantly using the proposed tool path planning method. 展开更多
关键词 cutter runout tool path optimization envelope surface five-axis machining geometric errors
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直槽微铣削中切削参数对铣刀跳动量的影响 被引量:3
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作者 马利杰 王西彬 +1 位作者 李勇峰 刘贯军 《机械工程学报》 EI CAS CSCD 北大核心 2014年第9期201-206,共6页
铣刀跳动是铣削振动的一种表现形式,其不仅加剧刀具的磨损,降低加工质量,严重时将使刀具产生崩刃甚至断裂,导致切削过程无法进行。基于45钢直槽微铣削试验,分析铣刀跳动量的基本特征。在此基础上,研究铣削参数对铣刀跳动量的影响规律,... 铣刀跳动是铣削振动的一种表现形式,其不仅加剧刀具的磨损,降低加工质量,严重时将使刀具产生崩刃甚至断裂,导致切削过程无法进行。基于45钢直槽微铣削试验,分析铣刀跳动量的基本特征。在此基础上,研究铣削参数对铣刀跳动量的影响规律,建立铣削参数与铣刀跳动量之间的非线性关系模型。研究结果表明,直槽微细立铣削时,立铣刀在各方向上的跳动量大小依次如下:槽宽方向(Y方向)>进给方向(X方向)>铣刀轴向(Z方向);铣削参数是影响铣刀跳动量的主要因素,其显著性水平依次如下:铣削速度vc>轴向切深H>进给速度f;基于正交试验建立的铣刀跳动量非线性关系模型具有较好的拟合效果,可以用于相应条件下铣刀跳动量的预报和控制。 展开更多
关键词 微细立铣削 直槽 切削参数 铣刀跳动量
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球头微铣刀径向跳动放大影响因素研究 被引量:2
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作者 刘畅 吴春亚 +2 位作者 王之军 李曦光 陈明君 《工具技术》 北大核心 2021年第10期45-50,共6页
微铣削高转速下,刀具绕中轴线不平衡的转动惯量会导致刀具变形并加大铣刀的径向跳动。本文针对刀具偏心量、微铣刀倾斜角、刀具悬伸量、主轴转速等参数增加时的径向跳动变化规律进行了有限元仿真。结果表明,随着刀具偏心量、倾斜角、悬... 微铣削高转速下,刀具绕中轴线不平衡的转动惯量会导致刀具变形并加大铣刀的径向跳动。本文针对刀具偏心量、微铣刀倾斜角、刀具悬伸量、主轴转速等参数增加时的径向跳动变化规律进行了有限元仿真。结果表明,随着刀具偏心量、倾斜角、悬伸量和主轴转速的增大,径向跳动比理论值有所增加,证明了存在径向跳动放大的情况,并通过实验证明径向跳动对加工精度的影响。 展开更多
关键词 微铣削 微铣刀 径向跳动
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五轴侧铣加工瞬时未变形切屑厚度计算模型 被引量:2
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作者 王立平 段飞宇 +2 位作者 佀昊 杜丽 袁星 《工程科学与技术》 EI CAS CSCD 北大核心 2020年第2期148-152,191,共6页
在五轴侧铣加工铣削力建模中,瞬时未变形切屑厚度的计算是铣削力预测的关键环节,直接影响着铣削力预测的精度与效率。为了提高铣削力的预测精度与效率,基于五轴机床空间运动分析,并考虑刀具径向跳动因素,提出了一种五轴侧铣加工瞬时未... 在五轴侧铣加工铣削力建模中,瞬时未变形切屑厚度的计算是铣削力预测的关键环节,直接影响着铣削力预测的精度与效率。为了提高铣削力的预测精度与效率,基于五轴机床空间运动分析,并考虑刀具径向跳动因素,提出了一种五轴侧铣加工瞬时未变形切屑厚度模型。首先,分析了五轴侧铣加工中铣削刃随刀具旋转、摆动与平移的复合运动规律,得到在不同刀位点处各切削刃的坐标位置;其次,考虑刀具径向跳动因素,提出了一种瞬时未变形切屑厚度的快速计算方法;最后,结合参数化厚度补偿的思想,对求解出的瞬时未变形切屑厚度进行修正,建立了一种等效厚度模型。将本文提出的等效厚度模型与现有的圆弧模型和线性迭代精确模型应用于算例中进行仿真。结果表明:等效厚度模型更加接近迭代精确值,平均误差率仅为1.37%,其与圆弧模型的平均误差率相比降低了8.35%,一定程度上提高了瞬时未变形切屑厚度的预测精度;在保证了预测精度的前提下,该模型相比于线性迭代模型将瞬时未变形切屑厚度的预测效率提高了10倍以上,在五轴侧铣加工铣削力预测中具有良好的应用前景。 展开更多
关键词 瞬时未变形切屑厚度 五轴侧铣加工 刀具径向跳动 参数化误差补偿
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德国BKG球磨式切粒机故障分析与解决方法
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作者 李然 《聚酯工业》 CAS 2019年第1期46-48,共3页
针对德国BKG球磨式切粒机日常生产中出现的故障情况,如切刀跳动幅度过大,切粒形状偏差,换向阀压力控制传感器异常,加热管故障问题,水系统电动蝶阀不动作等进行了故障的分析,提出了预防措施,有效地保证了BKG切粒机的平稳运行,减少设备故... 针对德国BKG球磨式切粒机日常生产中出现的故障情况,如切刀跳动幅度过大,切粒形状偏差,换向阀压力控制传感器异常,加热管故障问题,水系统电动蝶阀不动作等进行了故障的分析,提出了预防措施,有效地保证了BKG切粒机的平稳运行,减少设备故障率,优化设备备品备件,节约生产成本。 展开更多
关键词 BKG切粒机 切刀跳动 压力控制传感器 加热管
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大型板类零件圆弧面铣削加工技术研究与应用 被引量:2
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作者 李文杰 余小兵 +2 位作者 李崇智 田静 胡余平 《中国重型装备》 2022年第3期61-65,共5页
针对大型板类零件圆弧面三轴机床高精度圆铣削精度控制问题,从加工原理、机床精度、加工误差等方面进行分析,完成了内圆弧面和外圆弧面三轴数控机床铣削加工技术方案论证,通过减少数控机床多轴联动次数,选用合理的程序步距角,消除刀具误... 针对大型板类零件圆弧面三轴机床高精度圆铣削精度控制问题,从加工原理、机床精度、加工误差等方面进行分析,完成了内圆弧面和外圆弧面三轴数控机床铣削加工技术方案论证,通过减少数控机床多轴联动次数,选用合理的程序步距角,消除刀具误差,采取有效的检测控制手段,能够实现零件内外圆弧面的高精度加工。该圆弧面加工技术对于同类圆弧面结构的零件铣削加工具有很好的借鉴意义。 展开更多
关键词 板类零件圆弧面 圆心角 步距角 残留高度 刀齿径向跳动
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Variable-step integration method for milling chatter stability prediction with multiple delays 被引量:18
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作者 ZHANG XiaoJian XIONG CaiHua +1 位作者 DING Ye XIONG YouLun 《Science China(Technological Sciences)》 SCIE EI CAS 2011年第12期3137-3154,共18页
This paper analyzes the stability of milling with variable pitch cutter and tool runout cases characterized by multiple delays,and proposes a new variable-step numerical integration method for efficient and accurate s... This paper analyzes the stability of milling with variable pitch cutter and tool runout cases characterized by multiple delays,and proposes a new variable-step numerical integration method for efficient and accurate stability prediction. The variable-step technique is emphasized here to expand the numerical integration method,especially for the low radial immersion cases with multiple delays. First,the calculation accuracy of the numerical integration method is discussed and the variable-step algorithm is developed for milling stability prediction for single-delay and multiple-delay cases,respectively. The milling stability with variable pitch cutter is analyzed and the result is compared with those predicted with the frequency domain method and the improved full-discretization method. The influence of the runout effect on the stability boundary is investigated by the presented method. The numerical simulation shows that the cutter runout effect increases the stability boundary,and the increasing stability limit is verified by the milling chatter experimental results in the previous research. The numerical and experiment results verify the validity of the proposed method. 展开更多
关键词 variable-step numerical integration method MILLING chatter stability prediction multiple delays variable pitch cutter cutter runout
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Feedrate scheduling method for constant peak cutting force in five-axis flank milling process 被引量:6
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作者 Liping WANG Xing YUAN +1 位作者 Hao SI Feiyu DUAN 《Chinese Journal of Aeronautics》 SCIE EI CAS CSCD 2020年第7期2055-2069,共15页
It is extremely important to select appropriate feedrates for the stable machining of parts with ruled surface in modern aviation industrial applications.However,the current studies take too much time to achieve this ... It is extremely important to select appropriate feedrates for the stable machining of parts with ruled surface in modern aviation industrial applications.However,the current studies take too much time to achieve this goal.Therefore,this paper presents an efficient feedrate optimization method for constant peak cutting force in five-axis flank milling process.The solution method of the instantaneous undeformed chip thickness(IUCT)is proposed using least squares theory with the cutter entry angle and feedrate as variables.Based on this method,an explicit analytical expression of the peak cutting force for each cutting point is established.Furthermore,a feedrate scheduling method is developed to quickly solve the appropriate feedrate under constant peak cutting force.To verify the proposed IUCT model,the fitting IUCT is compared with the accuracy data at different feedrates.Additionally,some experiments of five-axis flank milling are conducted to demonstrate the effectiveness of the peak force model and the feedrate scheduling method.And the surface roughness before and after feedrate scheduling is detected.The results show that the proposed feedrate scheduling method can quickly adjust the feedrate and ensure constant peak force during machining.At the same time,the surface quality is kept at a high level. 展开更多
关键词 cutter runout Feedrate scheduling Force control Instantaneous undeformed chip thickness Peak cutting force
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Elliptical model for surface topography prediction in five-axis flank milling 被引量:3
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作者 Liping WANG Shuyi GE +3 位作者 Hao SIa Liwen GUAN Feiyu DUAN Yuzhe LIU 《Chinese Journal of Aeronautics》 SCIE EI CAS CSCD 2020年第4期1361-1374,共14页
In five-axis flank milling operations,the intersecting surfaces of different cutting edges create roughness on the milled surfaces that cannot be ignored in situations with strict requirements,especially in aeronautic... In five-axis flank milling operations,the intersecting surfaces of different cutting edges create roughness on the milled surfaces that cannot be ignored in situations with strict requirements,especially in aeronautical manufacturing.To focus on motion problems in milling operations,this paper presents a new model that utilizes elliptical paths as cutting edge trajectories on 3D surface topography machined by peripheral milling.First,the cutter parallel axis offset and location angle are considered,which change the location of the ellipse center and intersection point of the cutting edges.Then,through the proposed model,the predicted surface topography is obtained,and the factors that affect the development tendency of roughness are analyzed.Next,the effects of the cutter location position(CLP)geometric parameters,cutter parallel axis offset and curvature on the roughness are evaluated by a numerical simulation.Finally,machining tests are carried out to validate the model predictions,and the results show that the surface topography predictions correspond well with the experimental results. 展开更多
关键词 cutter runout Elliptical paths Five-axis flank milling Surface topography Workpiece curvature
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