Cutting temperature,tool wear,and tool life in heat-pipe-assisted end-milling operations

In this paper, using the specifications of nodal points on a nonuniform rational B-spline (NURBS) curve of three degrees with respect to NURBS curve parameter and defining the coefficients for the velocity and acceleration vectors on these points, a new method is presented to design a tool path via C² PH spline curves. Values of the velocity/acceleration vector coefficients corresponding to the nodal points on the original NURBS curve are computed by pattern search algorithm. To this end, the normal distance between the constructed C² PH spline curve and its corresponding original NURBS curve is considered as the objective function. Using combination of the time-dependent feed rate interpolation in the acceleration/deceleration phase of the motion and the constant feed rate interpolation in the middle region of the motion, the position commands of the designed NURBS-based C² PH spline curve are generated. Several improved NURBS-based C² PH spline curve following tasks were implemented with pseudo-derivative feedback feed forward (PDFF) controller. The experimental and simulation results confirm that the devised interpolator with designed PDFF controller is not only feasible for machining the complicated tool path represented in the improved NURBS-based C² PH spline form but also yields satisfactory contouring performance under variable feed rate.     

基于Foley参数法反算三次NURBS曲线的算法研究

非均匀有理B样条(NURBS)方法已成为定义工业产品几何形状的唯一数学描述方法.工程实践中,常需要通过曲线已知的一批型值点反算曲线.针对三次NURBS曲线反算问题,采用矩阵形式来表示三次NURBS曲线,由已知的型值点及其权因子,利用Foley参数法确定节点矢量,并推导出以抛物条件即贝塞尔条件作为边界条件构造附加方程,反算出三次NURBS曲线的控制点及其权因子.曲线拟合结果表明,该方法生成的插值曲线具有良好的光滑性,很好地适用于工程实践.     

Degree reduction of NURBS curves

Higher degree curves are used in applications because they are easier to manipulate interactively but require heavy computation. Most of the equations for curves used popularly in CAD software are of degree 2 and 3, because two curves of degree 3 can guarantee 2nd derivative continuity at the connection point. This study proposes a different but simpler method than any put forward before to deal with degree reduction of free-form curves. The reduced curves use the simplest knot vector type, i.e., the open uniform knot vector. Unlike other methods, this study does not modify or refine the knot vectors but perturb the control points globally. After obtaining an initial condition, a radiating web-like search algorithm is applied to detect the optimum positions. These NURBS curve formats reach basic industrial standards for CAD/CAM/CNC applications. By defining a global bound error function, this algorithm can achieve an optimum solution not only for NURBS curves but also Bézier/B-spline curves.     

NURBS及其自由变形

在分析 NURBS曲线、曲面与其参数域之间映射关系的基础上 ,建立了 NURBS实体和其参数域之间的映射关系 ,并进一步发现了基于 URBS的由变形与三参数 NU RBS实体之间的联系和自由变形的实质 ,即对三参数 NURBS实体的参数施了形状约束。将这一思想进一步推广到控制晶格顶点和权因子 ,则是我们下一步的工作     

NURBS output based tool path generation for freeform pockets

A robust method is proposed to generate tool paths for NURBS-based machining of arbitrarily shaped freeform pockets with islands. Although the input and output are all of higher-degree NURBS curves, only one simple category of geometric entities, i.e., line segments, is required for initial offsetting and for detecting and removing self-intersecting loops. Furthermore, using those linear non-self-intersecting offsets as the legs of NURBS control polygons, NURBS-format tool paths can be smoothly reconstructed with G¹-continuity, no overcutting, no cusps, and global error control. Since all operations involved in computing tool path curves are linear geometric calculations, the method is robust and simple. Examples with integrated rough and finish cutting tool paths of pockets demonstrate the usefulness and effectiveness of this method.     

五轴联动数控加工的刀具路径优化方法研究

为解决五轴联动加工复杂曲面过程中的刀具路径不连续问题,提出了五轴数控的刀具路径优化方法。通过五轴NC代码的坐标变换还原有效切削路径,对切削路径进行误差约束下的非均匀有理B样条(NURBS)曲线拟合。对旋转轴路径采用五次样条曲线进行插值,建立切削路径和旋转轴路径的参数映射关系,通过机床逆运动变换求解C2连续的平动轴路径。实验表明,经过该方法优化后,切削路径和各驱动轴运动路径具有良好的平滑性,显著提高了五轴加工曲面精度和表面质量。     

The redefinition of B-spline curve

This paper proposes a new formula of B-spline curve. The new formula generates exact same shape as that of the original B-spline curve formula but has different basic functions and knot vector. This formula requires the number of knots to be the same as the number of control points. This property of the new formula enables us to select the knot vector automatically even in case of nonuniform and to generate spline with relative constant speed. Some experimental results demonstrate its usefulness and quality.     

Real-time variable feed rate NURBS curve interpolator for CNC machining

This paper presents a real-time control algorithm based on Taylor’s expansion for implementing variable feed rate non-uniform rational B-spline (NURBS) curve interpolators using a digital signal processor for precision CNC machining. To efficiently compute the NURBS curve and its derivatives in real-time, an effective method is proposed. The variable feed rate NURBS curve interpolator can be used to realise the ACC/DEC before feed rate interpolation in which the ACC/DEC (acceleration/deceleration) planning on the feed rate command executes before the interpolation takes place, so that the path command errors caused by conventional ACC/DEC planning using the post feed rate interpolation can be effectively eliminated. To demonstrate the performance of the proposed algorithm, an X-Y table driven by two servomotors is controlled to track command paths represented by multiple blocks of NURBS curves. Experimental results verify the effectiveness of the proposed method.     

节点矢量影响NURBS曲线的规律研究与应用

以非均匀有理B样条（Non uniform rational B-spline, NURBS）曲线理论为基础,证明修改节点矢量对NURBS曲线的影响具有局部性,推导修改节点矢量引起的NURBS曲线变化量的计算式,提出修改节点矢量影响NURBS曲线的一般规律。对计算机辅助图形设计（Computer aided geometric design, CAGD）中曲线局部修改的实例进行试验研究,证明了修改节点矢量可以实现对NURBS曲线的局部修改,实现曲线交互式设计。对NURBS插值曲线节点因子调节法中航空压气机叶片边缘测量的实例进行了试验研究,证明可以获得拟合误差最小的叶片型面测量点NURBS插值曲线。试验研究证明所提出的“节点矢量影响NURBS曲线的一般规律”是正确的和可行的。     

数控刀位点的B样条精确拟合

为了满足现代NURBS曲线加工的要求,提出了把数控刀位点进行分段并按照用户设定精度进行快速拟合的一种算法。在拟合的过程中,通过不断地分析逼近误差,调整节点矢量,进行最小二乘拟合,直至使生成曲线达到规定的精度。利用上述方法进行最小二乘拟合时,建立的矩阵方程存在大量的零元素,采用了新的数据结构来存储矩阵方程,节省了内存空间,简化了求解步骤,获得了较快的计算速度。     

Modeling of the residual kinematic errors of coordinate measuring machines using LaserTracer system

It is complex and divergent for the conventional motion controllers to process various G codes using different interpolation algorithms. This impairs programming efficiency and robustness of the controller. In this paper, we propose the universal non-uniform rational B-splines (NURBS)-based interpolator which can simplify the architecture of interpolation in spite of interpreting different kinds of inputs. Direct conversion of long G01 and G02/G03 numerical control (NC) segments to NURBS segment is first implemented. The fitting of multiple short segments into a continuous and smooth NURBS segment is then carried out. More importantly, the universal NURBS-based interpolator utilizes the Cox–de Boor algorithm which is highly efficient and can take advantage of the parallel computing scheme to accelerate the processing speed. Furthermore, due to the construction of real-time environment, the proposed algorithm enables interpretation, look-ahead functions, and motion control to work simultaneously. A 2D NC program possessing hundreds of short G01 segments and long segments (i.e., G02, G03, and long G01) is tested on an in-house developed XY-table with a PC-based motion controller. The results have shown the effectiveness and feasibility of the proposed real-time NURBS-based interpolator.     

烟气轮机动叶片的参数化建模及加工仿真

运用NURBS曲线拟合算法将节点插入算法应用到动叶片截面型线造型中,采用UG软件中的NURBS样条曲线构造器功能在多个截面上准确绘制出动叶片的截面曲线造型,并利用NURBS曲面造型模块生成烟气轮机动叶片的实体模型。对零件结构特点进行工艺分析,运用UG的加工模块进行加工仿真,生成刀具轨迹并进行试验加工,为后续烟气轮机动叶片的数控加工提供依据。     

CNC codes conversion from linear and circular paths to NURBS curves

A novel approach is proposed for converting NC files of G01/G02/G03 codes into NURBS curves. The NC points are first acquired from an NC file composed of lines and arcs. A segmentation algorithm based on the angles and lengths evaluated from adjacent points is then used to subdivide the entire group of points into segments. An error-bounded constrained curve fitting algorithm is implemented to fit each segment of points into a curve, maintaining the accuracy, smoothness and boundary continuity between the curves. The chord errors between the NC points and the fitted curves are controlled, which ensures the accurate recovery of NC paths. Also, a knot insertion algorithm is proposed to determine the appropriate number of control points automatically, allowing effective fitting of all segments. Several examples are presented to demonstrate the feasibility of the proposed approach.     

Real-time PH-based interpolation algorithm for high speed CNC machining

Various methods for parametric interpolation of non-uniform rational B-spline (NURBS) curves have been proposed in the past. However, the errors caused by the approximate nature of the NURBS interpolator were rarely taken into account. This paper proposes an integrated look-ahead algorithm for parametric interpolation along NURBS curves. The algorithm interpolates the sharp corners on the curve with the Pythagorean-hodograph (PH) interpolation. This will minimize the geometric and interpolator approximation errors simultaneously. The algorithm consists of four different modules: a sharp corner detection module, a PH construction module, a feedrate planning module, and a dynamics module. Simulations are performed to show correctness of the proposed algorithm. Experiments on an X?CY table confirm that the developed method improves tracking and contour accuracies significantly compared to previously proposed algorithms.     

三次NURBS样条曲线插补加工螺旋转子建模与加工研究

提出在螺旋转子加工制造过程中,采用三次NURBS样条曲线插补替代通常的微直线段插补;建立了螺旋转子端面摆线段三次NURBS样条曲线方程.在Pro/E软件上比较了三次样条插补曲线和理论摆线之间的精度误差.最后通过在立式加工中心上比较了采用三次NURBS样条插补和采用微直线段插补的加工精度和加工效率,采用三次NURBS样条插补加工取得了理想的效果.     

自由曲线轮廓加工的圆弧样条刀具路径研究

给出了一种平面曲线轮廓的圆弧样条拟合及刀具路径生成算法，该算法面向零件轮廓的光顺性刀具路径生成，通过应用曲线的曲率关系，对以NURBS表示的被拟合自由曲线按参数递增的方向用G^1连续的圆弧或直线段逐段拟舍，并生成相应的圆弧样条刀具路径，从而实现零件曲线轮廓表面的光顺加工。实例计算和分析结果证明了该算法具有计算稳定性好、计算效率高的优点，易于在数控加工中实现。     

FREE-FORM SURFACE RECON-STRUCTION BASED ON NURBS TO SERIAL CROSS-SECTIONS

A new method for recovering shape from cross-sectional contours with complex branchingstructures is presented. First, each branching problem by providing an intermediate contour using dis-tance function and image processing technology is solved. Then, all contours are divided into severalgroups of simple contours. For each group, a NURBS curve is fitted to contour points in each sectionwithin a given accuracy on a common knot vector.Finally, the NURBS surface skinning of these con-tours is performed for providing a smooth geometric model. The method is suitable to reproduce theobject by NC machining or rapid prototyping. Some results demonstrate its usefulness and feasibility.     

Fast NURBS interpolation based on the biarc guide curve

In parametric spline interpolation, the real-time parameter update is a crucial step which will directly affect the processing performance such as the feed rate fluctuation, the contour error, the online computational effort, etc. The use of Taylor approximation interpolation method to identify the next interpolate point will cause large feed rate fluctuation due to the accumulation error and the truncation error, which will affect the machining quality. As there is no accurate analytic expression between the parameter u and arc length S and the mapping between them is nonlinear, and in order to reduce the feed rate fluctuation and light computation requirement for online interpolation, the paper first samples the tool path with step parameter and Gauss integration, with the sampled points being in the coordinate system defined by parameter u and arc length S. Then, the sampled points are fitted into the guide curve with the use of the biarc fitting method, and the analytic expression between parameter u and arc length S is established. The biarc so derived can be used to realize a fast NURBS interpolation and the simulation results validate the reliability and effectiveness of the proposed method.     

临界曲率值分割曲线尖角的NURBS曲线插补

为兼顾插补含尖角NURBS曲线的精度与速度,提出尖角分割且速度修正插补算法。由插补弦高误差限、法向加速度及其导数约束,得满足插补精度及机床动力学性能的临界曲率;用大于临界曲率的局部极大曲率及临界曲率分割NURBS曲线为是否包含尖角的若干子段;用S曲线加减速算法规划各子段进给速度,并用段间速度及位移协调关系修正各段加速度及其导数,使各段加减速时间为整数倍插补周期。在相同约束条件下,分别用曲率单调无速度修正、尖角分割无速度修正及尖角分割有速度修正算法,规划一条含大曲率尖角NURBS曲线插补速度,并用一阶泰勒级数展开算法插补该曲线。对比结果表明尖角分割且有速度修正算法可稳定得到较高插补精度,因此该算法可用于含大曲率尖角NURBS曲线高速度高精度加工。     

基于NURBS的弧面凸轮运动特征曲线的修正计算

利用非均匀有理B样条(NURBS),对弧面凸轮的运动特征曲线进行了修正计算.就型值点与节点矢量的确定方法、权因子的选取与优化、控制顶点的反算等修正中的关键问题,进行了较为详细地分析.通过比较B样条和NURBS修正曲线的位移误差,表明用NURBS修正后的误差明显小于用B样条修正后的误差.