共查询到19条相似文献,搜索用时 156 毫秒
1.
铣削加工过程中刀具的磨损是产生曲面加工误差的重要原始误差,将刀具磨损引起的误差通过建立的误差模型进行定量补偿,是虚拟制造中的一项关键技术。研究了虚拟制造环境下基于球头铣刀磨损的曲面加工误差补偿,建立了与加工参数相关的球头铣刀磨损模型,用以衡量球头铣刀切削刃磨损量,提出球头铣刀铣削加工误差补偿方法,并经实验验证有效。 相似文献
2.
球头铣刀刀具磨损建模与误差补偿 总被引:3,自引:0,他引:3
针对刀具磨损度量方式和模型建立的问题,以球头刀具为研究对象,提出球头铣刀刀具磨损的度量方式,建立球头刀具磨损模型.以复映磨损在硬度较软加工材料上的方式测量球头刀具磨损,确定刀具磨损模型系数,给出刀具磨损模型系数确定的具体实现方法.加工试验验证球头刀具磨损度量方式的合理性和所建立刀具磨损模型的正确性,同时针对数控铣削加工中球头铣刀刀具磨损引起的误差提出离线仿真误差补偿算法,给出离线仿真误差补偿算法的具体实现步骤,通过建立的刀具磨损引起的加工误差模型仿真获得加工走刀步的误差.对于误差超差的走刀步,预先修改数控加工(Numerical control,NC)程序,保证实际加工零件满足精度要求.误差补偿验证试验表明所提出的离线仿真误差补偿算法的正确性和有效性. 相似文献
3.
将刀具磨损引起的误差通过建立的误差模型进行预测,是虚拟制造中的一项关键技术.通过分析影响刀具磨损的切削参数,针对硬表面的加工材料建立了基于相对切削时间的球头铣刀磨损模型,提出了虚拟制造环境下考虑球头铣刀磨损的复杂曲面加工误差预报方法.实验结果表明:该误差模型预报是有效的,并且为曲面加工误差预测、提高曲面加工精度和效率提供了理论依据. 相似文献
4.
5.
6.
7.
《计算机集成制造系统》2014,(4)
根据表面形貌的定义,将球头铣刀加工表面分离为宏观的形状误差和微观的表面粗糙度两部分,综合运用几何建模和神经网络对表面形貌进行仿真预测。利用图形矩阵变换原理和矢量运算法则,推导出球头铣刀相对于工件的运动轨迹方程,建立了基于MATLAB软件的三维表面形貌仿真模型对形状误差进行预测。借助于MATLAB软件,通过反复训练建立了BP神经网络表面粗糙度预测模型。通过实验验证了仿真预测模型的准确性,表明所建立的模型具有有效的预测作用。 相似文献
8.
对用立铣刀和用球头铣刀精加工球曲面时所产生的误差进行比较,分析合理步距角的计算方法,编制了采用球头刀加工球面的宏程序,确保了加工质量和加工效率的统一。 相似文献
9.
10.
铣刀广泛用于船舶、医疗等各领域零部件的加工,由于刀具磨损直接影响工件的加工质量和加工效率,因此,针对工件加工过程中立铣刀侧刃的不规则磨损难以精确检测的问题,提出一种自适应拍摄角度的磨损误差补偿方法。通过分析拍摄角度对不同形状磨损域的影响规律,结合刀具结构参数建立刀具磨损量与拍摄角度之间的映射模型,实现因拍摄角度不同而导致的刀具磨损检测误差自动偿算。不同拍摄角度的实验结果表明,磨损检测精度大于95%,验证了磨损检测误差自补偿方法的可行性。该研究方法与思路对后续刀具磨损测量的高精度智能化检测具有借鉴意义。 相似文献
11.
针对不同走刀路径下的复杂曲面加工过程进行球头铣刀铣削Cr12MoV加工复杂曲面研究,分析不同走刀路径下铣削力和刀具磨损的变化趋势。试验结果表明:通过对比分析直线铣削和曲面铣削过程中的最大未变形切屑厚度,可以得出单周期内曲面铣削的力大于直线铣削过程的力,铣削相同铣削层时环形走刀测得的切削力普遍大于往复走刀测得的切削力;以最小刀具磨损为优化目标,运用方差分析法分析得出不同走刀路径的影响刀具磨损的主次因素,同时利用残差分析方法建立球头铣刀加工复杂曲面刀具磨损预测模型,并通过试验进行验证。 相似文献
12.
为深入研究微织构排列形式对微织构理刀具的抗磨减摩机理的影响,分别从理论、仿真及试验等方面对最优的微织构排布形式进行研究。首先,建立微织构在刀具前刀面的数学模型及仿真模型。其次,通过试验验证仿真结果的准确性。仿真及试验研究均发现,变密度微织构球头铣刀的铣削性能优于均匀分布密度的微织构球头铣刀。最后,运用模糊评价法优选最优的铣削性能的微织构球头铣刀,优化结果表明,两排织构间距先为200 μm,再为150 μm,最后为175 μm的微织构球头铣刀的铣削性能最好。该项研究使刀具具有良好的抗磨减磨性,提高加工效率及被加工工件的表面质量。 相似文献
13.
14.
Geometric error compensation for five-axis ball-end milling by considering machined surface textures
Guoqiang Fu Tengda Gu Hongli Gao Yu’an Jin Xiaolei Deng 《The International Journal of Advanced Manufacturing Technology》2018,99(5-8):1235-1248
Arbitrarily adjusting tool poses during error compensation may affect the quality of surface textures. This paper presents one tool center limitation-based geometric error compensation for five-axis ball-end milling to avoid the unexpected machined textures. Firstly, the mechanism of cutter location generation with cuter contact (CC) trajectory is analyzed. Due to zero bottom radius of ball-end cutter, CC points of the surface are only related to the tool center of the cutter. Realizing that, tool center limitation method of ball-end milling is established based on the generation of movements of all axes in order to ensure the machined textures. Then, geometric error compensation of ball-end milling is expressed as optimizing rotation angles of rotary axes by limiting tool centers of cutter locations. Next, particle swarm optimization (PSO) is intergraded into the geometric error compensation to obtain the compensated numerical control (NC) code. The limited region for particles of rotation angles is established, and moving criterion with a mutation operation is presented. With the help of the tool center limitation method, fitnesses of all particles are calculated with the integrated geometric error model. In this way, surface textures are considered and geometric errors of the machine tool are reduced. At last, cutting experiments on five-axis ball-end milling are carried out to testify the effectiveness of the proposed geometric error compensation. 相似文献
15.
16.
An Enhanced Force Model for Sculptured Surface Machining 总被引:1,自引:0,他引:1
The ball-end milling process is used extensively in machining of sculpture surfaces in automotive, die/mold, and aerospace industries. In planning machining operations, the process planner has to be conservative when selecting machining conditions with respect to metal removal rate in order to avoid cutter chipping and breakage, or over-cut due to excessive cutter deflection. These problems are particularly important for machining of sculptured surfaces where axial and radial depths of cut are abruptly changing. This article presents a mathematical model that is developed to predict the cutting forces during ball-end milling of sculpture surfaces. The model has the ability to calculate the workpiece/cutter intersection domain automatically for a given cutter path, cutter, and workpiece geometries. In addition to predicting the cutting forces, the model determines the surface topography that can be visualized in solid form. Extensive experiments are performed to validate the theoretical model with measured forces. For complex part geometries, the mathematical model predictions were compared with experimental measurements. 相似文献
17.
18.
Zhiqiang Liang Shidi Li Tianfeng Zhou Peng Gao Dongdong Zhang Xibin Wang 《The International Journal of Advanced Manufacturing Technology》2018,97(1-4):39-50
Micro ball-end milling is an efficient method for the fabrication of micro lens array molds. However, it is difficult to meet the machining quality of micro dimple molds due to the wear and breakage of the milling cutter, which presents large challenges for designing geometric structure and edge strength of micro ball-end mills. In this study, a new configuration of a micro ball-end mill for micro dimple milling is designed and named the micro conical surface ball-end mill. The cutting edge is formed by intersecting the conical surface and the inclined plane. A practical grinding method is proposed based on the kinematic principle of the six-axis computer numerical control (CNC) grinding machine for micro conical surface ball-end mills and is validated by grinding simulations and experiments. Micro dimple milling experiments are conducted on the hardened die steel H13 to investigate the cutting performance of the mill. The milling force, the micro dimple roundness error, and the tool wear morphology are observed and analyzed. The results show that the radial milling force is more stable and the wear resistance is improved for the micro conical surface ball-end mill compared to the traditional micro spiral blade ball-end mill. Therefore, a more stable roundness at the entrance hole of the micro dimple can be obtained by using this design after a number of micro dimples have been milled. 相似文献
19.
《Machining Science and Technology》2013,17(3):431-448
Abstract The ball-end milling process is used extensively in machining of sculpture surfaces in automotive, die/mold, and aerospace industries. In planning machining operations, the process planner has to be conservative when selecting machining conditions with respect to metal removal rate in order to avoid cutter chipping and breakage, or over-cut due to excessive cutter deflection. These problems are particularly important for machining of sculptured surfaces where axial and radial depths of cut are abruptly changing. This article presents a mathematical model that is developed to predict the cutting forces during ball-end milling of sculpture surfaces. The model has the ability to calculate the workpiece/cutter intersection domain automatically for a given cutter path, cutter, and workpiece geometries. In addition to predicting the cutting forces, the model determines the surface topography that can be visualized in solid form. Extensive experiments are performed to validate the theoretical model with measured forces. For complex part geometries, the mathematical model predictions were compared with experimental measurements. 相似文献