本文選題：閉式葉輪 + 高速銑削　； 參考：《陜西科技大學(xué)》2017年碩士論文

【摘要】：在透平機械領(lǐng)域中,通常選用整體結(jié)構(gòu)性好,強度高的軸流式閉式葉輪作為工作部件,從而提高設(shè)備的運轉(zhuǎn)性能。但由于閉式葉輪結(jié)構(gòu)復(fù)雜,流道扭曲劇烈,葉片間空間狹小,加工要求高,所以軸流式閉式葉輪的刀位規(guī)劃難度高,加工難度大。在制造業(yè)中,通常采用焊接的方式,通過分部加工葉輪的部位,然后組合在一起,最后完成葉輪的制造。采用這種組合式加工工藝,不利于提高加工效率,在產(chǎn)品制造周期中所占的比重很大,而且葉輪的結(jié)構(gòu)參數(shù)、工作性能都無法得到保證。所以采用五軸數(shù)控加工技術(shù)、高速銑削技術(shù)、以及高端的CAM軟件技術(shù),對軸流式閉式葉輪的五軸高速銑削加工工工藝進行系統(tǒng)的研究,對提高這類結(jié)構(gòu)復(fù)雜、零件整體剛性差的產(chǎn)品加工效率和加工質(zhì)量有很好的借鑒意義。首先,為了保證軸流式閉式葉輪的建模精度,對建模原理和技術(shù)進行分析研究,采用三次B樣條技術(shù),用MATLAB軟件反求出葉輪的控制點,將計算的控制點數(shù)據(jù)導(dǎo)入UG軟件,在UG軟件中完成閉式葉輪的葉片曲面、輪轂面、包覆面的建模,為后續(xù)的CAM編程以及相關(guān)數(shù)學(xué)計算做好了鋪墊。其次,對五軸高速銑削加工技術(shù)進行分析,對軸流式閉式葉輪的加工要求和加工難點進行分析,確定加工步驟,初始毛坯的結(jié)構(gòu)、加工使用的刀具、夾具安全高度的計算、夾具的設(shè)計,設(shè)計加工工藝卡,從而完成軸流式閉式葉輪的加工工藝規(guī)劃。再次,采用數(shù)學(xué)計算方法,利用MATLAB軟件完成了軸流式閉式葉輪流道的最大內(nèi)接圓柱面的計算,確定了定軸粗加工的范圍,用金屬有限元切削分析仿真軟件確定了切削前角的范圍,最后用定軸加高速銑削的方式完成閉式葉輪的刀位軌跡規(guī)劃。粗加工完成后,針對殘留量不均勻,殘留量較多的問題,采用余量偏置、分層疊加的刀位軌跡規(guī)劃方式,結(jié)合CAM軟件的管道模塊加工原理,完成半精加工的刀位軌跡計算。在半精加工的CAM設(shè)置里,改變精加工切削參數(shù),完成刀位軌跡的計算,在精加工插補方面,采用五軸樣條插補代替直線插補,對三次多項式樣條插補的原理、計算步驟進行了深入的研究,設(shè)計了五軸樣條插補流程圖。最后,通過CAM軟件HyperMill結(jié)合以上各階段研究的刀位規(guī)劃成果,分別對軸流式閉式葉輪的各個加工階段,按照加工工藝的順序完成CAM編程,完成刀位軌跡的計算,然后將HyperMill的mof刀位文件轉(zhuǎn)換成APT文件,利用UG的后處理模塊開發(fā)五軸樣條插補后處理,運用Tcl語言編寫相關(guān)的后處理程序語句,編寫完成后對刀位文件進行后處理,然后在仿真模擬軟件上模擬NC程序,最后在機床上對軸流式閉式葉輪進行實際加工驗證,證明了軸流式閉式葉輪的加工工藝正確性。
[Abstract]:In the field of turbine machinery, the axial flow closed impeller with good overall structure and high strength is usually chosen as the working part, thus improving the operation performance of the equipment. But because the structure of the closed impeller is complex, the flow channel is distorted violently, the space between the blades is narrow, and the machining requirement is high, the tool position planning of the axial flow closed impeller is difficult and the processing difficulty is great. In manufacturing, welding is usually adopted, the parts of impeller are processed by parts, then assembled together, finally the manufacture of impeller is finished. This kind of combined processing technology is not conducive to improving the processing efficiency and occupies a large proportion in the manufacturing cycle of the product, and the structural parameters and the working performance of the impeller cannot be guaranteed. Therefore, five-axis NC machining technology, high-speed milling technology and high-end CAM software technology are used to systematically study the five-axis high-speed milling process of axial flow closed impeller, which is complex to improve this kind of structure. The machining efficiency and quality of parts with poor overall rigidity are of great significance. First of all, in order to ensure the modeling accuracy of the axial flow closed impeller, the modeling principle and technology are analyzed and studied. The control points of the impeller are obtained by using the cubic B-spline technique and the MATLAB software, and the calculated data of the control points are imported into UG software. The modeling of the blade surface, hub surface and cladding surface of the closed impeller is completed in UG software, which lays the groundwork for the subsequent CAM programming and related mathematical calculation. Secondly, the processing technology of five-axis high speed milling is analyzed, the machining requirements and difficulties of axial flow closed impeller are analyzed, the processing steps, the structure of initial blank, the tool used for machining, the safety height of fixture are calculated. Jig design, design processing process card, so as to complete the axial flow closed impeller processing process planning. Thirdly, by using the mathematical calculation method and using MATLAB software, the calculation of the maximum inner connection cylinder surface of the axial flow closed impeller runner is completed, and the range of the fixed axis rough machining is determined. The range of cutting front angle is determined by the metal finite element cutting simulation software. Finally, the tool path planning of closed impeller is completed by means of fixed axis and high speed milling. After rough machining, aiming at the problem of uneven residue and more residue, the tool path planning method of residual bias and stratified superposition was adopted, and the tool path calculation of semi-finished machining was completed by combining the pipe module machining principle of CAM software. In the CAM setting of semi-finished machining, the cutting parameters are changed to complete the calculation of the tool path. In the interpolation, the five-axis spline interpolation is used to replace the linear interpolation, and the principle of cubic polynomial spline interpolation is given. A five-axis spline interpolation flow chart is designed. Finally, the CAM software HyperMill is used to complete the CAM programming according to the sequence of the machining technology to complete the calculation of the tool position trajectory for each processing stage of the axial flow closed impeller by combining the tool position planning results of the above stages. Then the mof tool position file of HyperMill is converted into APT file, the five axis spline interpolation post processing is developed by UG post processing module, and the relevant post processing program statements are written by Tcl language, and the tool position file is processed after the completion of the program. Then the NC program is simulated on the simulation software. Finally, the machining technology of the axial flow closed impeller is verified by actual machining on the machine tool, which proves that the machining technology of the axial flow closed impeller is correct.
【學(xué)位授予單位】：陜西科技大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2017
【分類號】：TG659;TK14

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