考虑刀具姿态的铣削力系数在线辨识方法  

Online Identification Method for Milling Force Coefficients Considering Cutter Orientation

作　　者：段现银[1] 张泽州 朱泽润 陈晨[1] 谢良喜[1] DUAN Xianyin;ZHANG Zezhou;ZHU Zerun;CHEN Chen;XIE Liangxi(School of Mechanical Engineering,Wuhan University of Science and Technology,Wuhan 430081,China;School of Mechanical and Electrical Engineering,Wuhan University of Engineering,Wuhan 430205,China)

机构地区：[1]武汉科技大学机械工程学院,武汉430081 [2]武汉工程大学机电工程学院,武汉430205

出　　处：《航空制造技术》2025年第6期48-57,共10页Aeronautical Manufacturing Technology

基　　金：国家自然科学基金(51605346,52005201)。

摘　　要：航空构件的智能化加工对在线监测与故障预警提出了迫切需求,尤其是在薄壁件和复杂曲面件的五轴铣削加工过程中,铣削力的精确预测对于优化工艺至关重要。然而,五轴铣削加工的工艺条件与切削几何特性更加复杂,为铣削力系数的精确辨识带来巨大挑战。为此,本文提出了一种考虑刀具姿态的铣削力系数在线辨识方法,通过单个刀具旋转周期内的五轴加工铣削力信号,实现了铣削力系数的精确在线辨识。基于五轴铣削力预测的机械力学模型,系统考虑刀具倾角的影响,建立了刀具-工件接触区域边界的特征线、交线及投影线的解析表达式,并在平均未变形切屑厚度模型中引入了考虑刀具倾角的瞬时未变形切屑厚度,进而构建了包含刀具姿态影响的五轴铣削力系数辨识模型。通过五轴铣削加工与切削力在线监测试验,分别开展了未考虑刀具姿态和考虑刀具姿态的铣削力系数辨识及铣削力预测,并对不同模型在五轴铣削力预测中的误差进行了对比分析。试验结果表明,考虑刀具姿态的铣削力系数辨识方法能够显著提高五轴铣削力预测的精度,研究为航空构件智能加工过程的在线监测、故障预警及工艺优化提供了重要的方法基础和理论支撑。Intelligent machining of aerospace components has created an urgent demand for online monitoring and fault prediction,particularly in five-axis milling of thin-walled parts and complex curved surfaces.Accurate milling force prediction is critical for process optimization.As the commonly used crucial technique in components milling,five-axis milling is of the advantage of excellent adaptability,enabling its application in gas turbine blade,aero-engine blade and turbine components.However,the complex process conditions and cutting geometry in five-axis milling present significant challenges for precise identification of milling force coefficients.This paper proposes an online identification method for milling force coefficients that considers cutter orientation.By analyzing the milling force signals within a single cutter rotation cycle,precise online identification of milling force coefficients is achieved.Based on a mechanical model for five-axis milling force prediction,the influence of cutter inclination is systematically considered.Analytical expressions are developed for the characteristic lines,intersection lines,and projection lines defining the cutter-workpiece contact area boundaries.Additionally,an instantaneous undeformed chip thickness model incorporating cutter inclination is introduced,leading to the construction of a five-axis milling force coefficient identification model that accounts for cutter orientation effects.Five-axis milling experiments and online monitoring of cutting forces were conducted to compare the milling force coefficient identification and prediction accuracy with and without considering cutter orientation.Error analyses were performed for different models in five-axis milling force prediction.The experimental results show that the proposed method significantly improves the accuracy of milling force prediction.This study provides an essential methodological foundation and theoretical support for online monitoring,fault prediction,and process optimization in the intelligent machin

关 键 词：铣削力系数 五轴加工 刀具姿态 参数化模型 在线监测 智能加工 

分 类 号：TG54[金属学及工艺—金属切削加工及机床] TG501.2