航空发动机复杂曲面零件数控加工刀具轨迹规划研究分析

整体叶盘等复杂曲面零件是航空发动机中的核心零件,其数控加工技术中的关键是刀具轨迹的规划技术.本文针对当今国内外复杂曲面的数控加工刀具轨迹规划的研究现状和发展进行了分析.主要对复杂曲面数控加工中三种主要刀具的轨迹规划进行了对比分析,并对刀具轨迹规划中的关键技术进行了分析,包括：轨迹拓扑、轨迹参数、干涉避免和刀轴控制的算法理论和适用特点,并对刀具轨迹规划中的曲线插补和刀具组合方向进行了分析和展望,为后续研究提升零件数控加工效率和质量打下了基础.     

剃齿刀修形砂轮斜截面法数控精密加工机理研究

剃齿刀修形砂轮侧面突起是弦长弦高比很大的圆弧,现有数控插补算法无法加工出符合精度要求的修形砂轮。针对这一缺陷,提出斜截面法放大弦高从而减小弦长弦高比的方法,推导加工曲线的方程,并结合算例,获得离散点坐标和加工刀具轨迹。结果表明通过斜截面法放大弦高的加工方式可以获得较高精度的插补轨迹。同时也为大曲率小圆弧曲面的数控加工奠定了一定的理论基础。     

A general,fast and robust B-spline fitting scheme for micro-line tool path under chord error constraint

The discontinuity of linear tool path(or G01 blocks) brings about unnecessary feedrate deceleration and fluctuation during machining. To improve the continuity, the linear tool path is usually smoothed by the local transition method or the global fitting method. For micro-line tool path, the transition method will significantly decrease the machining efficiency and introduce feedrate fluctuation. The global fitting method cannot be directly used in the NC interpolation because the indispensable chord error checking and iterative fitting processes are computation-intensive. This paper presents a general, fast and robust B-spline fitting scheme under chord error constraint for high speed interpolation of micro-line tool path. The proposed fitting method guarantees the chord error by utilizing the strong convex hull property of B-spline curves. The knot vector and control points are initially generated by a progressive iterative approximation method and locally refined to conform to the chord error constraint by using an analytical method. The analytical approximation and refining methods avoid solving a linear system of equations that is necessary in the standard B-spline fitting method. The feasibility and efficiency of the proposed scheme has been verified via simulations and experiments. Compared with the traditional fitting method, the proposed scheme can strictly constrain the chord error and can significantly decrease the computational load. Compared with the transition scheme, the proposed scheme can significantly increase the machining efficiency for the same micro-line tool path under the same chord error tolerance.     

NURBS曲线实时插补中S型加减速算法的研究

针对在高速高精度加工过程中非均匀B样条曲线(non-uniform rational B-spline,NURBS)的实时插补时,机床加减速容易出现冲击或者振荡现象,提出了S型加减速(S-shape ADC/DEC)前瞻方法。建立了曲线的S型加减速离散采样模型,提出了S型曲线加减速前瞻算法,通过此算法可以根据实际插补轨迹的几何特性,能够自适应地确定加减速点。仿真结果表明该算法可以在保证加工精度的同时有效消除加减速过程中对机床的冲击,提高加工精度。     

基于中间消息语言和Qt库的刀具轨迹系统的设计与实现

刀具轨迹系统作为数控系统的重要组成部分，加工前可以在计算机上模拟显示实际加工全过程，实际加工时对刀具进行实时监控。介绍了基于蓝天新型数控系统的刀具轨迹系统的设计与实现，包括中间消息语言通信机制的研究和Qt库的裁剪。     

基于中间消息语言和Qt库的刀具轨迹系统的设计与实现

刀具轨迹系统作为数控系统的重要组成部分,加工前可以在计算机上模拟显示实际加工全过程,实际加工时对刀具进行实时监控。介绍了基于蓝天新型数控系统的刀具轨迹系统的设计与实现,包括中间消息语言通信机制的研究和Qt库的裁剪。     

数控铣床常用刀具的合理选用

正确的选择和使用数控铣床加工中的刀具,不仅可以优化加工工艺方案,简化数控加工程序的编制,而且可以提高加工效率,提高数控加工产品的加工质量,降低生产成本。数控加工工艺中的重要内容是切削用量的确定和刀具的选择,也是数控加工程序编制的主要依据。要根据工件材料的性能、加工工序、机床的加工能力、切削用量以及其它相关因素合理选用刀具及刀柄。     

具有自光顺功能的五坐标样条插补控制器

针对现行复杂曲面加工中常常采用的五轴联动线性插补加工方法速度、精度较低,数控文件较大等缺点,开发了一种具有自光顺功能的五坐标样条曲线插补器。介绍了运动控制器中样条曲线的构造方法和曲线实时插补方法。针对具有流线型设计要求的工件的加工,控制器在插补实施之前,对数控程序文件中提供的刀心点序列进行光顺性判断,对不符合光顺判别条件的刀心点进行修正。加工实例表明,本文方法可以完全克服五轴线性插补方法的不足之处。初步应用表明:该控制器对轮廓外形具有光顺性要求的工件具有良好的加工效果。     

基于极坐标投影法的五轴加工刀具路径生成法

针对五轴加工中刀具矢量变化较大且易产生干涉的问题,提出了基于极坐标投影法的五轴加工刀具路径生成法。利用微分几何理论计算得自由曲面的法矢、主曲率及其极值,利用极坐标投影法获得刀轴矢量,并求得可能的干涉区域;应用等距偏移曲面法计算出曲面数控精加工刀位数据,并通过控制切削残留高度的方法求得切削行距。结果表明,极坐标投影法可以得到无干涉的五轴加工刀位数据,并可以获得均匀变化的刀轴矢量。     

基于预估-校正公式的参数曲线插补算法

为减小插补输出速度的波动,提出基于预估 校正公式的参数曲线插补算法.该算法包括插补预处理和实时插补两部分.插补预处理采用S曲线加减速算法规划插补速度,得出插补速度与时间关系.实时插补用Akima插值法计算插补速度,用五阶龙格 库塔法计算参数的初值,用五阶预估 校正公式计算下一插补参数.对比研究了提出的算法与基于泰勒级数展开插补算法对同一条参数曲线的插补效果,结果表明,与基于泰勒级数展开算法相比,在数控加工中,提出的算法可减小插补输出速度波动,提高机床运动的平稳性,提高加工精度.     

Study on Control Algorithm for Continuous Segments Trajectory Interpolation

In CNC machining, the complexity of the part contour causes a series of problems including the repeated start-stop of the motor, low machining efficiency, and poor machining quality. To relieve those problems, a new interpolation algorithm was put forward to realize the interpolation control of continuous sections trajectory. The relevant error analysis of the algorithm was also studied. The feasibility of the algorithm was proved by machining experiment using a laser machine to carve the interpolation trajectory in the CNC system GT100. This algorithm effectively improved the machining efficiency and the contour quality.     

基于OpenGL的STEP—NC数控铣削系统加工仿真

介绍了在VisualC骄境下,利用OpenGL图形函数库开发基于STEP—NC的数控铣削系统的加工仿真。给出OpenGL与VC＋＋的接口机制,说明了加工仿真中工件和刀具的建模方法以及工件和刀具的动态求交来实现材料的去除效果,模拟了真实情况下的加工过程。     

Digital Manufacture Techniques for Large Hydro Turbine's Blades

Blades are one of the vital components and most difficulty in manufacturing of large hydro turbines.In order to cost-effectively and productively manufacture these kinds of blades,a series of digital techniques in manufacturing have been devel- oped,which includes digital design of hydro turbine blades based on manufacture' requirements,Computer-aided location and the machined error evaluation by using 3-dimensional digitized measuring,tool path generation strategy to meet requirements of en- hancing machining efficiency and controlling deviation in NC machining,tool path generation and NC machining simulation by es- tablishing a virtual NC machining environment for blades,and reasonable and feasible strategy and the systematic scheme for man- ufacturing of large blades by using 5-axis simultaneous CNC machining.The developed digital manufacture techniques have been successfully applied in manufacturing of both the large Kaplan and Francis hydraulic turbine blades;it shows that higher efficiency and the better surfaces finish accuracy can be achieved.     

Tricept型并联机床曲面加工的刀轨规划

研究了Tricept型并联机床采用平底刀加工曲面时的刀轨规划问题. 首先简要地介绍了机床的结构组成,并对机床的逆运动学及其位姿作业空间进行了分析. 在此基础上,给出了刀具干涉检验及刀具位姿作业空间检验的有效算法. 借助于传统五坐标数控机床曲面加工的等残高刀轨路径生成方法,提出了适用于Tricept型并联机床的刀轨规划算法.     

参数方程曲线的直接插补算法研究

插补技术是数控系统的核心技术,插补算法的优劣直接影响数控系统的加工效率.通常渐开线、螺旋线等非圆复杂曲线在数控系统中用小段圆弧或直线来逼近,这使得数控代码的数据量极大,且逼近误差较大,计算机辅助编程也很复杂.为此,本文提出一种非圆复杂曲线的插补算法,该算法表达精确、运算速度快;此外,还分析了该插补算法的理论误差,并给出了通用的刀具半径补偿方法.     

自由曲面砂带磨削轨迹规划与误差控制分析

砂带磨削是提高自由曲面工件型面精度和表面质量的重要手段之一,针对目前自由曲面砂带磨削加工在效率和精度方面存在不足,基于砂带磨削加工的特性,提出了一种基于加工精度控制的自由曲面砂带磨削加工的轨迹规划方法。首先,对实现无曲率干涉的接触轮半径及满足加工允差的接触轮宽度进行了公式推导,结合轮与曲面上加工点主曲率关系,通过双倍体的遗传算法优选出满足自由曲面要求的加工允差,并获取无曲率干涉加工需求的接触轮尺寸参数。然后,基于加工点的主曲率方向实现加工轨迹的自适应宽行距规划,同时采用柔顺处理算法对其点导动规划过程中当曲面存在扭曲时的磨头潜在的大幅往复摆动运动进行了柔顺处理,获得了行距稳定且满足加工时接触轮在磨削点处始终与自由曲面达到最佳贴合效果的磨削轨迹。最后,应用该方法对某航空发动机叶片型面进行轨迹规划,并在数控砂带磨床上进行了加工验证。结果表明：规划的磨削加工轨迹能够使得叶片轮廓截面精度较好地满足加工要求,提高了叶片型面的表面质量和精度,证实了该方法的有效性和实用性。本文提出的轨迹规划方法可科学合理地控制曲面预期加工允差,解决了在自由曲面砂带磨削过程中因接触轮尺寸参数选择不当而引起的局部干涉的计算难题,能够有效提高砂带磨削加工的效率和精度。     

Circular Interpolation Algorithms of 5-Axis Simultaneous CNC System

Spatial circular arc can be machined conveniently by a 5-axis NC machine tool.Based on the data sampling method,circular interpolation in two-dimensional plane is discussed briefly.The key is to solve the problem of circular center ex- pressed in the workpiece coordinate system by means of the transformation matrix.Circular interpolation in three-dimensional space is analyzed in detail.The method of undetermined coefficient is used to solve the center of the spatial circle and the method of coor- dinate transformation is used to transform the spatial circle into the XY-plane.Circular arc in three-dimensional space can be ma- chined by the positional 5-axis machining and the conical surface can be machined by the continuous 5-axis machining.The velocity control is presented to avoid the feedrate fluctuation.The interpolation algorithms are tested by a simulation example and the inter- polation algorithms are proved feasible.The algorithms are applied to the 5-axis CNC system software.     

Stewart型并联机床直线插补步长的研究

为了提高Stewart型并联机床运动学精度,文章研究并联机床末端运动轨迹的直线插补步长和非线性插补误差的关系.提出了采用曲率法度量非线性运动误差和插补步长之间的关系,基于以上方法,建立了度量并联机床非线性强度的曲率模型.通过数值仿真的方法,得出并联机床工作空间内非线性误差的分布规律,并得出整个机床工作空间内的最大曲率为0.0016.利用以上结论,在满足插补精度的前提下,选取较大的直线插补步长,提高了并联机床的加工效率.     

Adaptation of feed rate for 3-axis CNC high-speed machining

To improve the efficiency of CNC machining,assumptive transit circular arc is used to contour two adjacent moves together on the corner to make smooth paths. The radius of transit circular arc can be adjusted with contour accuracy,and the feed rate on the corner can be controlled through limiting the maximum feed rate of transit circular arc segment. A look-ahead algorithm for a series of moves is proposed for speed adjustment in advance,which avoids the occurrence of overload of cutting tool on the corner and reduces the servo track error of parts on the corner or of circular arc move. Equivalent trapezoidal velocity profile is used to analyze the speed of S-curve velocity profile and work out its accurate interpolation,which overcomes the disadvantage of looking up table to calculate feed rate approximately,hence high accuracy and fine surface quality can be obtained while the machining speed is high. The proposed methods can meet the requirements of real-time analysis of high-speed machining. The presented algorithm is effective and has been adopted by CNC system of newly developed high-speed milling machine.     

Study on Control Algorithm for Continuous Segments Trajectory Interpolation

In CNC machining,the complexity of the part contour causes a series of problems including the repeated start-stop of the motor,low machining efficiency,and poor machining quality.To relieve those problems,a new interpolation algorithm was put forward to realize the interpolation control of continuous sections trajectory.The relevant error analysis of the algorithm was also studied.The feasibility of the algorithm was proved by machining experiment using a laser machine to carve the interpola- tion trajectory in the CNC system GT100.This algorithm effectively improved the machining efficiency and the contour quality.