自由曲面平头立铣刀五轴加工铣削力预报  

Force Prediction Model for Five-axis Flat End Milling of Sculptured Surface

作　　者：郭明龙 魏兆成[1] 王敏杰[1] 李世泉 刘胜贤 GUO Minglong;WEI Zhaocheng;WANG Minjie;LI Shiquan;LIU Shengxian(Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education,Dalian University of Technology, Dalian 116024)

机构地区：[1]大连理工大学精密与特种加工教育部重点实验室

出　　处：《机械工程学报》2019年第7期225-233,共9页Journal of Mechanical Engineering

基　　金：辽宁省自然科学基金(201602174);中央高校基本科研业务费专项资金(DUT17GF213)资助项目

摘　　要：铣削力是优化工艺参数,设计机床、刀具和夹具的重要依据。针对自由曲面平头立铣刀五轴宽行加工,提出了一种基于空间限定法的刀刃接触区间解析算法,建立了考虑刀具偏心的铣削力预报模型。基于微分离散思想,自由曲面看成一系列微小斜平面,以斜平面平头立铣刀五轴加工为研究对象,参数化定义刀具几何、进给方向和工件三者间的任意关系,界定刀刃微元参与切削的条件,沿刀刃曲线搜索获得整个刀刃接触区间,结合微元铣削力模型,构建了平头立铣刀斜平面五轴加工铣削力模型,即可实现对自由曲面平头立铣刀五轴加工的铣削力预报,并推导出铣削力由刀具坐标系到工件坐标系的转换矩阵。刀刃接触区间仿真表明,该空间限定法与刀具接触区域限定法相比算法更简单,通用性更强;与实体法相比效率更高。铣削力试验表明,测量铣削力与预报铣削力在趋势和幅值上总体吻合良好,证明了该铣削力预报模型的有效性。Milling force is an important basis for optimizing process parameters, designing machine tools, cutters and fixtures. An analytical algorithm of in-cut cutting edge based on space constraint method is proposed for five-axis flat end milling of sculptured surface, and the prediction model of milling force is established considering cutter runout. Based on the idea of differential discretization, the sculptured surface can be assumed as a series of tiny inclined plane. The arbitrary relation between cutter geometry, feed direction and workpiece is defined by parameterization taking the five-axis flat end milling of inclined plane as the object of study. The conditions of cutting edge element involved in cutting are proposed, and the entire in-cut cutting edge is obtained by searching along the edge curve. Combined with the classical micro-unit milling force model, force prediction model for five-axis flat end milling of inclined plane can be established, then the force prediction for five-axis flat end milling of sculptured surface can be realized. Moreover, the transition matrix of milling force from cutter coordinate system to workpiece coordinate system can be derived. The simulation results show that the spatial constraint method is simpler and more versatile than the cutter workpiece engagement limitation method. The experiment results show that the predicted force is in good agreement with measured force in both trend and amplitude, which proves the validity of the milling force prediction model.

关 键 词：铣削力预报 刀刃接触区间 五轴宽行加工 自由曲面 平头立铣刀 

分 类 号：TG506[金属学及工艺—金属切削加工及机床]