五轴侧铣加工刀具路径生成及优化-机械电子工程专业论文.docx

AbstractIn the filed of mechanical manufacturing, research on machining complex free form surface, such as impeller of aircraft engine, screw propeller for boat, impeller of steam tur- bine, has been an area of focus for several years. Generally speaking, ball-end milling is the most spread technology currently used for free form or sculptured surface machining owing to the simple toolpath generation and wide range of applications, nevertheless the very poor processing efficiency and surface quality increases costing. To overcome the shortcomings of ball-end milling, flank milling(or called side milling) is adopted. However it is main- ly apply to ruled surfaces,and we cannot machine a ruled surface exactly unless the ruled surface is developable. Through research on the generation and optimization of tool trajec- tories, the cutter deflection will be decreased to satisfy the accuracy requirement. There are many commercial CAM softwares for implementing such functionality, Such as MAX-5T M . With MAX-5’s patented algorithm, 80% to 90% cutting errors will be decreased. Therefore research on the generation and optimization of tool trajectories play a significant role in promoting the development of the manufacturing of China.This thesis starts the discussion from differential geometry, the intial toolpaths are cal- culated by a kind of numerical methods. A method to approach and escape motions is proposed. The tool envelope surface is generated by quaternion interpolation and two- parameter family of spheres. Compute the signed distance which is considered to be the cutter errors between design surface and the swept surface. Factors such as tool parameters correlate with cutting errors have been discussed.Calculate the tool trajectories in manufacturing coordinate system by mapping model coordinate system to manufacturing coordinate system. Generated NC code through post processing, then verify the tool paths by simulation program. Then machining the ruled surfaces in