高速铣削数控编程基础算法的研究与实现
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摘要
高速切削是先进制造技术领域国内外学者研究的热点,具有传统数控加工无可比拟的优势。目前,该技术在欧、美、日国家已广泛使用,而在我国研究高速切削技术起步较晚,基础技术比较薄弱,尤其在切削机理、加工工艺、刀具新材料、数控等具有知识产权的技术方面,与国外相比,仍有较大差距。为此,本文结合国家和省级科研项目,对高速铣削加工数控编程技术进行了研究,取得了以下创新性成果。
1.研究了高速切削的编程策略,提出并实现了支持高速铣削加工的摆线刀轨生成算法,所生成的加工刀轨去除材料范围大、切削高硬材料性能好。
2.在研究传统识别加工残区粗加工算法的基础上,提出并实现了适合高速铣削自识别加工残区的粗加工环切刀轨生成算法,能有效延长刀具寿命、降低主轴振动、精简工序、提高型腔加工生产率。
3.借鉴高速公路“立交桥”匝道的设计思想,提出并实现了适合高速铣削加工的“立交桥”弯道精加工刀轨生成算法。
4.结合 NURBS 的曲线优势,提出并实现了面向复杂曲面的 3 轴联动高速铣精加工可变行距的螺旋线与 Zigzag 混合刀轨优化算法。
5.在分析研究 5 轴加工刀轨生成算法的基础上,提出并实现了用 5 次 NURBS直纹面拟合原加工刀轨面的局部防过切 5 轴联动铣削加工刀轨生成算法,该算法保证了全程刀位曲线的 C2连续性。
在上述研究成果的基础上,开发出了高速铣削自动编程原型系统,已在多个工程实例中应用,取得了满意的效果。
High Speed Machining (ab. HSM), is one of advanced manufacturingtechnologies, and has become the focus of scholars’ attention from oversea and ourhomeland. Compared to conventional NC machining strategies, it has several extraadvantages. Nowadays, it is widely applied to manufacture in U.S.A., Japan andthose countries located in Europe, but in China, the applied research of HSM juststarts, and basal technologies are also weak, especially in those technologiesincluding cutting theory and machining processing, new cutting-tool material andNC etc, Chinese almost haven’t proprietary intellectual property rights. So, we areengaged in research on this aspect, and fortunately some technologies of NCautomatic programming for HSM are put forward in the dissertation thanks toscience and technology funds from Jiangsu province and China. The mainachievements are as follows:
1. An algorithm on tool-path generation based on cycloid is put forward, aimingat some larruping technology characters and practical requirements of HSM. Cycloidmachining has advantages including progressively shaving material from the stock ina circular motion and machining high hard materials.
2. This dissertation proposes a tool-path generation algorithm on automaticrecognition uncut free pocketing for HSM, On the basis of research on the algorithmof the uncut free pocketing automatically recognized for conventional NC roughmachining operation. Results show that the method can prolong cutter life, dampvibration from spindle, simplify processes and enhance productivity.
3. The algorithm of tool-path generation, using the ideal that stereo-bridgesmoothly connects two speedways in different direction, is brought forward for HSMfinish machining operation. 4. An algorithm on tool-path generation, optimized through the use ofhelix-blend-Zigzag method and NURBS advantage, is put forward for HSM complex3-D surface machining.
5. On the basis of quantic NURBS rule-face fitting original any other face, agouge-free new algorithm on 5-axis tool-path generation is put forward for flank andend-face rough- finish milling. The tool-path, including CL-curve and tool
orientation generated by the algorithm, is smooth-C2-continuous.
According to the achievements above, the software of NC automaticprogramming prototype system for HSM is successfully developed, which has beenapplied to part machining in manufacture. The result of tests shows that it issatisfying.
1.研究了高速切削的编程策略,提出并实现了支持高速铣削加工的摆线刀轨生成算法,所生成的加工刀轨去除材料范围大、切削高硬材料性能好。
2.在研究传统识别加工残区粗加工算法的基础上,提出并实现了适合高速铣削自识别加工残区的粗加工环切刀轨生成算法,能有效延长刀具寿命、降低主轴振动、精简工序、提高型腔加工生产率。
3.借鉴高速公路“立交桥”匝道的设计思想,提出并实现了适合高速铣削加工的“立交桥”弯道精加工刀轨生成算法。
4.结合 NURBS 的曲线优势,提出并实现了面向复杂曲面的 3 轴联动高速铣精加工可变行距的螺旋线与 Zigzag 混合刀轨优化算法。
5.在分析研究 5 轴加工刀轨生成算法的基础上,提出并实现了用 5 次 NURBS直纹面拟合原加工刀轨面的局部防过切 5 轴联动铣削加工刀轨生成算法,该算法保证了全程刀位曲线的 C2连续性。
在上述研究成果的基础上,开发出了高速铣削自动编程原型系统,已在多个工程实例中应用,取得了满意的效果。
High Speed Machining (ab. HSM), is one of advanced manufacturingtechnologies, and has become the focus of scholars’ attention from oversea and ourhomeland. Compared to conventional NC machining strategies, it has several extraadvantages. Nowadays, it is widely applied to manufacture in U.S.A., Japan andthose countries located in Europe, but in China, the applied research of HSM juststarts, and basal technologies are also weak, especially in those technologiesincluding cutting theory and machining processing, new cutting-tool material andNC etc, Chinese almost haven’t proprietary intellectual property rights. So, we areengaged in research on this aspect, and fortunately some technologies of NCautomatic programming for HSM are put forward in the dissertation thanks toscience and technology funds from Jiangsu province and China. The mainachievements are as follows:
1. An algorithm on tool-path generation based on cycloid is put forward, aimingat some larruping technology characters and practical requirements of HSM. Cycloidmachining has advantages including progressively shaving material from the stock ina circular motion and machining high hard materials.
2. This dissertation proposes a tool-path generation algorithm on automaticrecognition uncut free pocketing for HSM, On the basis of research on the algorithmof the uncut free pocketing automatically recognized for conventional NC roughmachining operation. Results show that the method can prolong cutter life, dampvibration from spindle, simplify processes and enhance productivity.
3. The algorithm of tool-path generation, using the ideal that stereo-bridgesmoothly connects two speedways in different direction, is brought forward for HSMfinish machining operation. 4. An algorithm on tool-path generation, optimized through the use ofhelix-blend-Zigzag method and NURBS advantage, is put forward for HSM complex3-D surface machining.
5. On the basis of quantic NURBS rule-face fitting original any other face, agouge-free new algorithm on 5-axis tool-path generation is put forward for flank andend-face rough- finish milling. The tool-path, including CL-curve and tool
orientation generated by the algorithm, is smooth-C2-continuous.
According to the achievements above, the software of NC automaticprogramming prototype system for HSM is successfully developed, which has beenapplied to part machining in manufacture. The result of tests shows that it issatisfying.
引文
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