虚拟五轴侧铣加工过程建模与仿真分析  

Modeling and analysis for virtual fiveaxis flank milling process

作　　者：张立强[1] 王宇晗[2] 

机构地区：[1]上海工程技术大学机械工程学院,上海201620 [2]上海交通大学机械与动力工程学院,上海200240

出　　处：《工程设计学报》2011年第2期98-102,共5页Chinese Journal of Engineering Design

基　　金：国家自然科学基金资助项目(50875171);上海市优秀青年教师资助项目(gjd09003)

摘　　要：提出一种面向五轴侧铣加工的球头刀几何与力学模型,利用该综合模型可对复杂曲面加工进行几何仿真与切削力预测,对加工过程进行速度规划.切削工件几何模型采用深度元素法,通过与刀具模型之间的布尔操作实现材料去除过程,通过分析刀具与工件接触区域,得到刀具在不同瞬时的轴向范围及沿轴向各微元的切入角和切出角,转换为铣削力模型所需的几何信息.采用序列二次规划法优化进给速度,使机床工作在多个约束条件的最大潜能值内.整个规划过程随刀具与工件接触区域的变化而不断优化,研究工作为五轴侧铣加工过程提供了有力的分析工具.双叶片五轴侧铣加工仿真实验表明,在满足叶片精度条件下,采用优化进给速度可使零件加工效率提高约40%.A complete geometric and force model for fiveaxis flank milling was presented,and then geometric simulation and cutting forces prediction can be conducted based on the integrated model.Feedrate scheduling was planned based on the mechanistic model.The method selected for geometric stock modeling was the dexel approach.The cutter workpiece engagements defined the instantaneous intersection boundary between the cutting tool and the inprocess workpiece.From the CWE,the cutter entryexit angles and depth of cuts were found and used to calculate the instaneous cutting forces.The constrained optimization was solved by sequential quadratic programming and the machine was operated at threshold levels.The process was optimized by varying the feed as the toolworkpiece engagements vary along the tool path,and the research provided a powerful tool for analysing fiveaxis flank milling.Production time in flank milling dual blades was reduced considerably to 40% with the satisfaction of precision demands.

关 键 词：五轴 侧铣 几何仿真 力学模型 

分 类 号：TG506[金属学及工艺—金属切削加工及机床]