本文選題：五軸加工 + 可行域構(gòu)造��； 參考：《湘潭大學》2017年碩士論文

【摘要】：隨著現(xiàn)代工業(yè)化的飛躍式發(fā)展,對制造業(yè)也提出了更高的要求——產(chǎn)品性能優(yōu)、制造方法新、加工精度高及生產(chǎn)周期短。五軸加工以高速高精度高效率等特點被廣泛的應(yīng)用于自由曲面的加工,雖然五軸加工給制造業(yè)帶來了一種創(chuàng)新的、高優(yōu)勢的制造方法,但也因為其相對于普通數(shù)控機床外加了兩個額外旋轉(zhuǎn)軸,給加工中的工藝規(guī)劃帶來不少難點。本文在系統(tǒng)地研究了五軸加工相關(guān)理論和國內(nèi)外研究進展的基礎(chǔ)上,以提高自由曲面加工誤差精度與加工效率為目的,針對環(huán)形刀五軸加工自由曲面刀具軌跡規(guī)劃算法進行了基礎(chǔ)研究。通過對切削模型和干涉現(xiàn)象的分析,在刀軌規(guī)劃時將刀具干涉問題考慮在內(nèi),并以此為前提規(guī)劃出等弓高、等最大殘高刀具軌跡曲線。本文的主要內(nèi)容如下:首先,針對五軸加工中的單刀觸點在某刀具姿態(tài)下的干涉檢測問題,提出一種基于投影法與映射理論的干涉檢測算法,該算法可以有效地避免兩曲面間、線與曲面間的相交判斷計算。其思路為:根據(jù)環(huán)形刀的幾何形狀對其進行分解并建立數(shù)學表達式,通過投影得到可能發(fā)生干涉的曲面待測點,進行干涉檢測時將待測點的工件坐標值按映射理論反代入到環(huán)形刀各個數(shù)學表達式中,通過對比待測點與刀具表面映射點在Z軸方向的取值間接進行干涉判斷。為后續(xù)的無干涉刀具姿角可行域構(gòu)造奠定了基礎(chǔ)。其次,提出了一種基于定向距離理論的等弓高、等最大殘高刀具軌跡規(guī)劃算法。該算法能夠有效的減少因近似處理所帶來的規(guī)劃誤差,在容許誤差范圍內(nèi)最大限度地減少刀觸點和刀軌總數(shù)量。其規(guī)劃過程包括初步規(guī)劃與精確修正兩個步驟:首先根據(jù)圓弧近似法和微分幾何法對進給步長與側(cè)向行距進行初步計算,然后以基于定向距離理論的弓高、殘高誤差計算模型對進給步長與側(cè)向行距進行精確修正,最后通過遞推計算得到覆蓋整個工件曲面的刀軌曲線。該算法能夠有效的減少因近似處理所帶來的規(guī)劃誤差。最后,根據(jù)對五軸機床運動學原理、各聯(lián)動軸間相互關(guān)系的分析,提出了針對雙回轉(zhuǎn)工作臺AC型五軸機床刀軌刀位數(shù)據(jù)轉(zhuǎn)換計算方法,并在UG NX8.0/Post Builder系統(tǒng)中構(gòu)造臨時刀軌后置處理器。其后在Vericut軟件和Mikron UCP800 Duro五軸加工中心中分別進行加工仿真和實際加工,并與傳統(tǒng)算法及商用軟件MasterCAM 9.0的結(jié)果進行對比。實驗結(jié)果表明,采用本文算法進行刀軌規(guī)劃,既能有效地避免加工中干涉現(xiàn)象的發(fā)生,又能在滿足加工質(zhì)量的基礎(chǔ)上大大地提高加工效率。
[Abstract]:With the rapid development of modern industrialization, higher requirements have been put forward to the manufacturing industry, such as excellent product performance, new manufacturing method, high processing precision and short production cycle. Five-axis machining is widely used in free-form surface processing with the characteristics of high speed, high precision and high efficiency, although five-axis machining has brought an innovative, high-advantage manufacturing method to the manufacturing industry. But because of the addition of two additional rotating shafts to the NC machine tools, it brings many difficulties to the process planning. On the basis of systematically studying the theory of five-axis machining and the research progress at home and abroad, the purpose of this paper is to improve the accuracy and efficiency of free-form surface machining. In this paper, the basic research on tool path planning algorithm for free form surface machining with annular cutter is carried out. Based on the analysis of cutting model and interference phenomenon, the tool interference problem is taken into account in the tool path planning, and the tool trajectory curve of equal arch height and equal residual height is obtained on this premise. The main contents of this paper are as follows: firstly, an interference detection algorithm based on projection method and mapping theory is proposed to detect the interference of a single pole contact in five-axis machining under a tool attitude. The algorithm can effectively avoid the interference between two surfaces. Calculation of the intersection between lines and surfaces. The idea is to decompose the annular knife according to its geometric shape and establish its mathematical expression, and obtain the points to be measured by projecting the surface that may interfere. In the process of interference detection, the coordinate value of the workpiece to be measured is inversely inserted into the mathematical expressions of the ring cutter according to the mapping theory, and the interference judgment is made indirectly by comparing the values of the mapping points between the measured points and the mapping points of the tool surface in the Z axis direction. It lays a foundation for the construction of the feasible region of the pose angle of the non-interference cutting tool. Secondly, a tool path planning algorithm based on directional distance theory is proposed for equal bow height and equal maximum residual height. The algorithm can effectively reduce the planning error caused by approximate processing and minimize the total number of cutter contacts and tracks within the allowable error range. The planning process includes two steps: first, according to the arc approximation method and differential geometry method, the feed step size and the lateral distance are calculated, and then the bow height based on the directional distance theory is used. The calculation model of residual height error corrects the feed step size and the lateral distance accurately. Finally, the tool track curve covering the whole workpiece surface is obtained by recursive calculation. This algorithm can effectively reduce the planning error caused by approximate processing. Finally, according to the kinematics principle of the five-axis machine tool and the analysis of the interrelation between the linkage shafts, a method for calculating the tool path position data conversion of the AC type five-axis machine tool with double rotary table is presented. In UG NX 8.0 / Post Builder system, the post processor of temporary cutter rail is constructed. Then the machining simulation and actual machining were carried out in Vericut software and Mikron UCP800 Duro five-axis machining center, respectively, and compared with the results of traditional algorithm and commercial software MasterCAM 9.0. The experimental results show that the proposed algorithm can not only effectively avoid the interference in machining, but also greatly improve the machining efficiency on the basis of satisfying the machining quality.
【學位授予單位】：湘潭大學
【學位級別】：碩士
【學位授予年份】：2017
【分類號】：TG659

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