球头铣刀曲面多轴加工的刀具接触区半解析建模*

魏兆成; 王敏杰; 王学文; 赵丹阳

doi:10.3901/JME.2017.01.198

机械工程学报 >

2017 , Vol. 53 >Issue 1: 198 - 205

DOI: https://doi.org/10.3901/JME.2017.01.198

制造工艺与装备

球头铣刀曲面多轴加工的刀具接触区半解析建模^*

魏兆成 ,
王敏杰 ,
王学文 ,
赵丹阳

展开

1. 大连理工大学精密与特种加工教育部重点实验室大连 116024;
2. 鞍钢蒂森克虏伯汽车钢有限公司大连 116600

魏兆成(通信作者)，男，1981年出生，博士，副教授。主要研究方向为复杂曲面铣削力学/动力学。E-mail：wei_zhaocheng@dlut.edu.cn

网络出版日期: 2017-01-05

基金资助

* 国家自然科学基金(51205040)、中国博士后科学基金特别(2013T60280)、辽宁省自然科学基金资助项目(2014028005)和中央高校基本科研业务费专项资金(DUT14RC(3)047)资助项目; 20151225收到初稿，20160825收到修改稿;

收起

A Semi-analytical Cutter Workpiece Engagement Model for Ball End Milling of Sculptured Surface

WEI Zhaocheng ,
WANG Minjie ,
WANG Xuewen ,
ZHAO Danyang

Expand

1. Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education， Dalian University of Technology， Dalian 116024;
2. TKAS Auto Steel Co.， Ltd.， Dalian 116600

Online published: 2017-01-05

Fold

摘要

刀具接触区界定了切削过程刀具与工件的相互作用范围，是研究切削力学/动力学的基础，复杂曲面加工的刀具接触区往往呈现不规则几何形状且沿曲线刀具轨迹不断变化。针对球头铣刀复杂曲面多轴加工，提出一种刀具接触区半解析建模方法。基于微元离散和刚体旋转变换的思想，将一般复杂曲面加工看成是一系列微小斜平面加工的组合，并且认为球头铣刀斜平面多轴加工的刀具接触区，可由球头铣刀水平面三轴立铣加工的刀具接触区经刚体旋转变换而得。通过将切削余量材料看成是一系列微厚材料薄层的叠加，构建了球头铣刀水平面三轴立铣加工的刀具接触区解析模型，从而建立球头铣刀复杂曲面多轴加工的刀具接触区半解析模型。仿真实例分析了模型的精度和效率，结果表明该半解析模型能够精确高效地描述复杂曲面多轴加工的刀具接触区。

关键词： 刀具接触区; 复杂曲面加工; 球头铣刀

本文引用格式

魏兆成 , 王敏杰 , 王学文 , 赵丹阳 . 球头铣刀曲面多轴加工的刀具接触区半解析建模^*[J]. 机械工程学报, 2017 , 53(1) : 198 -205 . DOI: 10.3901/JME.2017.01.198

Abstract

Cutter workpiece engagement (CWE), which defines the interaction region between tool and workpiece, is the basis for studying mechanics and dynamics of cutting. In sculptured surface machining, the CWE usually appears irregular geometry and varies along curve path. A semi-analytical CWE model for multi-axis ball end milling of sculptured surface is presented. With the ideas of differential and rigid-body rotation transformation, general sculptured surface machining is considered as a combination of some small inclined plane machining, and the CWE of inclined plane machining can be obtained by rotating that of horizontal plane machining. By taking the cutting allowance material as a combination of some thin parallel slices, an analytical CWE model for ball end milling of horizontal plane is proposed. And thus the CWE model for multi-axis ball end milling of sculptured surface machining is obtained. The precision and efficiency of proposed model are investigated by some simulation examples. Simulation results reveal that the developed model can describe CWE in multi-axis ball end milling of sculptured surfaces with high precision and efficiency.

Key words： cutter workpiece engagement; sculptured surface machining; ball end mill

参考文献

[1] IMANI B M, SADEGHI M H, ELBESTAWI M A. An improved process simulation system for ball-end milling of sculptured surfaces [J]. Int. J. Mach. Tools Manuf., 1998, 38(9)：1089-1107.

[2] 倪其民, 李从心, 阮雪榆. 基于实体造型的球头铣刀三维铣削力仿真 [J]. 上海交通大学学报, 2001, 35(7)：1003-1007.

NI Qimin, LI Congxin, RUAN Xueyu. Cutting forces simulation of ball-end milling based on solid modeling [J]. Journal of Shanghai Jiao Tong University, 2001, 35(7)：1003-1007.

[3] YANG Yun, ZHANG Weihong, WAN Min, et al. A solid trimming method to extract cutter–workpiece engagement maps for multi-axis milling [J]. Int. J. Mach. Tools Manuf., 2013, 68(9-12)：2801-2813.

[4] KIM G M, CHO P J, CHU C N. Cutting force prediction of sculptured surface ball-end milling using Z-map [J]. Int. J. Mach. Tools Manuf., 2000, 40(2)：277-291.

[5] KIM G M, KIM B H, CHU C N. Estimation of cutter deflection and form error in ball-end milling processes [J]. Int. J. Mach. Tools Manuf., 2003, 43(9)：917-924.

[6] LAZOGLU I. Sculpture surface machining: A generalized model of ball-end milling force system [J]. Int. J. Mach. Tools Manuf., 2003, 43(5)：453-462.

[7] 张臣, 周儒荣, 庄海军, 等. 基于Z-map模型的球头铣刀铣削力建模与仿真 [J]. 航空学报, 2006, 27(2)：347-352.

ZHANG Chen, ZHOU Rurong, ZHUANG Haijun, et al, Modeling and simulation of ball end milling force based on z-map model [J]. Acta Aeronautica et Astronautica Sinica, 2006, 27(2)：347-352.

[8] WEI Zhaocheng, WANG Minjie, CAI Yujun, et al. Prediction of cutting force in ball-end milling of sculptured surface using improved Z-map [J]. Int. J. Adv. Manuf. Technol., 2013, 68(5-8)：1167-1177.

[9] WEI Zhaocheng, WANG Minjie, ZHU Jianning, et al. Cutting force prediction in ball end milling of sculptured surface with Z-level contouring tool path [J]. International Journal of Machine Tools and Manufacture, 2011, 51(5)：428-432.

[10] OZTURK B, LAZOGLU I. Machining of free-form surfaces. Part I: Analytical chip load [J]. Int. J. Mach. Tools Manuf., 2006, 46(7-8)：728-735.

[11] OZTURK B., LAZOGLUI., ERDIM H., Machining of free-form surfaces. Part II: Calibration and forces [J]. Int. J. Mach. Tools Manuf., 2006, 46(7-8)：736-746.

Options

文章导航

模态框（Modal）标题

摘要

本文引用格式

Abstract

参考文献