二轴联动数控加工球头铣刀的虚拟制造模型

分析了三种不同定义的螺旋刃口曲线的异同和与优劣 ,给出了二轴联动数控加工时不同截形的螺旋沟槽球头铣刀的刃口、沟槽及砂轮截形、相对进给速度等设计模型 ,并通过实得沟槽及计算机模拟结果进行了验证 ,认为借助该模型可获得较理想的球头回转铣刀。     

球头铣刀刃口曲线的求解及螺旋沟槽的二轴联动数控加工

给出了球头螺旋铣刀三种不同螺旋刃口曲线的求解公式和二轴联动数控加工时砂轮的截形和相对运动求解模型,根据实得沟槽的模型和计算机模拟结果分析了存在的不足,并给出了相应的后处理方法。     

球面铣刀制造中的数学模型研究

介绍了球面铣刀成形原理、刃口曲线求解模型、刃口曲线相关参数的优化模型、磨制后刀面的机构和相应数学模型，并用实例验证上述模型的可靠性，最后还讨论了砂轮磨损对刃口曲线的影响。为球面铣刀的国产化提供了参考。     

关于二轴联动数控加工球头铣刀的几点说明

指出了二轴联动数控加工采用与轴线成定角螺旋刃口的球头铣刀时存在的设计与制造难题 ,并给出了相应的处理方法及相关模型 ,计算机虚拟制造结果验证了该方法的正确性和可行性。     

三沟槽等螺旋角带角圆铣刀设计的数学模型

给出了带角圆的柱面铣刀上与经线成定角的螺旋刃口的连续刃口曲线模型 ,并结合三个沟槽的沟槽截形设计公式和 NC加工相关注记 ,为这种铣刀的设计及 NC加工提供了参考     

虚拟制造中基于刀具磨损的复杂曲面加工误差补偿

基于数控铣削加工仿真系统,研究了在虚拟制造环境下对球头铣刀磨损引起的曲面加工误差的预测与补偿。建立了与加工参数相关的球头铣刀磨损模型,用于预测球头铣刀切削刃的磨损量,提出了球头铣刀铣削加工误差的补偿方法,并通过实验验证了该方法的有效性。     

球头铣刀曲面多轴加工的刀具接触区半解析建模

刀具接触区界定了切削过程刀具与工件的相互作用范围,是研究切削力学/动力学的基础,复杂曲面加工的刀具接触区往往呈现不规则几何形状且沿曲线刀具轨迹不断变化。针对球头铣刀复杂曲面多轴加工,提出一种刀具接触区半解析建模方法。基于微元离散和刚体旋转变换的思想,将一般复杂曲面加工看成是一系列微小斜平面加工的组合,并且认为球头铣刀斜平面多轴加工的刀具接触区,可由球头铣刀水平面三轴立铣加工的刀具接触区经刚体旋转变换而得。通过将切削余量材料看成是一系列微厚材料薄层的叠加,构建了球头铣刀水平面三轴立铣加工的刀具接触区解析模型,从而建立球头铣刀复杂曲面多轴加工的刀具接触区半解析模型。仿真实例分析了模型的精度和效率,结果表明该半解析模型能够精确高效地描述复杂曲面多轴加工的刀具接触区。     

球头立铣刀的建模设计及仿真系统的研究

以球头立铣刀的正交螺旋形刀刃曲线为基础。设计了锥形砂轮刃磨铣刀前后刀面的方式。分别推导与建立了具有等法向前角的前刀面、等主后角的后刀面的球头立铣刀的数学模型。并根据模型开发了球头立铣刀的计算机仿真设计与分析软件。     

等法向前角和等径向后角微细球头铣刀刃磨研究

微细球头铣刀因其在制造复杂的曲面和零部件方面具有很大的优势而广泛应用于微机械加工领域。目前多轴数控磨削方法仍是实现微细球头铣刀批量化制造的主要方法,但是由于微细球头铣刀尺寸小,误差敏感性大,在刃磨过程中难以保证其制造精度和质量,因此迫切需要精确高效的刃磨方法来提高微细球头铣刀制造精度,降低其刃磨制备难度。为此,基于球面等导程螺旋线切削刃曲线,提出了用于等法向前角前刀面的刃磨模型。为了实现球部和圆柱形部分的后刀面的平滑连接,提出了等径向后角后刀面的刃磨模型。基于提出的刃磨模型和6轴CNC磨床运动原理,通过Matlab编程求解等法向前角和等径向后刀面微细球头铣刀刃磨过程中机床各轴运动轨迹。最后,通过磨削仿真和实验成功制造了直径为0.5mm的硬质合金微细球头铣刀,其最大几何误差不超过5%,从而验证了磨削方法的正确性和有效性。     

虚拟制造中基于刀具磨损的复杂曲面加工误差补偿

铣削加工过程中刀具的磨损是产生曲面加工误差的重要原始误差,将刀具磨损引起的误差通过建立的误差模型进行定量补偿,是虚拟制造中的一项关键技术。研究了虚拟制造环境下基于球头铣刀磨损的曲面加工误差补偿,建立了与加工参数相关的球头铣刀磨损模型,用以衡量球头铣刀切削刃磨损量,提出球头铣刀铣削加工误差补偿方法,并经实验验证有效。     

球头铣刀切削力计算机预报模型的数值仿真

借助建立的铣刀切削力、扭矩和切削功率的计算机预报模型 ,对平前刀面球头铣刀的切削性能进行了数值仿真研究 ;通过分析各种切削参数对切削性能的影响规律 ,获得了不同切削条件下球头铣刀切削力和扭矩的特征和变化趋势     

非数控加工球头铣刀的主干数学模型

汇总介绍了非数控加工球头铣刀前、后刀面的基本原理和主干数学模型 ,为低成本批量生产球头铣刀提供了理论依据     

铲齿成形铣刀“成形”问题的探讨

分析了铲齿成形铣刀用钝重磨后铣刀廓形的变化情况 ,推导了铲磨成形铣刀重磨后的齿形计算公式 ,指出此类铣刀重磨后其设计廓形将发生变化 ,并提出用调整刀具前角的方法对齿形重磨误差予以补偿     

在ANCA TX7+数控磨床上加工PCBN型面铣刀负倒棱的工艺方法

用普通工具磨床难以加工复杂型面铣刀的负倒棱,一般的数控磨床没有现成的负倒棱加工程序。本文以球头铣刀为例,介绍了通过人工建模在ANCA-TX7+数控磨床上加工带负倒棱型面铣刀的编程和工艺方法。     

铲齿成形铣刀重磨误差的研究

提出了γｆ＞０的铲齿成形铣刀因重磨引起的廓形高度误差的计算方法,通过实例计算,分析了重磨误差的规律,并提出了减小重磨误差的措施。     

An approach to the evaluation of multivariate data during ball end milling free-form surface fragments

We present a method for investigating the process of ball end milling, a technology widely used in tool making and moulding. We analyse the main features of free-form surfaces used in this technology, and propose a sequence of steps to identify the most suitable milling strategy. The basic idea of such a sequence lies in the definition of the tangible fragments of free-form surfaces applicable to tool making. Tangible fragments represent the parts of tooling and signed radii that can distinguish both the active and transitional surfaces of tooling. Free-form surface fragments were selected since they are capable of securing definiteness in measurement of roughness parameters and surface errors. We investigated the operation capability of solid ball end milling cutters in terms of cutting tool edge micro-geometry. Cutting edge radius (r_n) and roughness parameters of the tool edge were measured to determine the relationship between new and worn tool edges. Roughness parameters were measured at different parts of the machined surfaces, which take on typical features of dies and moulds, such as inclined wall, ridge lines, valley lines, as well as, the active surfaces defined by signed radii. Surface error such as scallop height, gouging, tolerances and actual signed radii were measured at transitive surfaces. The traditional approach of evaluating roughness parameters was used to determine the suitability of factors such as milling operation, milling strategy and direction of milling. In addition, traditional approaches such as relationships, distributions and histograms were also used. We applied Khattree–Naik’s plot, which proves its suitability to visualise all the data being measured in the same units: microns and millimetres. Characteristic features of the ball end milling process, such as tool edge micro-geometry, geometry of the machined surface, and unit length of the transitive surface were applied in Khattree–Naik’s plots. We found that this plot was capable of processing multivariate data to distinguish specific markers of the quality of machined surfaces, which are produced in ball end milling.     

整体硬质合金球头立铣刀的重磨试验研究

以高速加工的整体硬质合金球头立铣刀的重磨试验为例,介绍了为适应不锈钢的高速加工,铣刀结构参数、涂层而进行的调整,并介绍了铣刀的重磨流程。试切表明:重磨刀具的平均寿命接近新刀。     

整体式立铣刀三维建模及切削力预测研究

针对立铣刀三维建模困难及铣削时切削力难以预测等问题,根据微分几何原理建立立铣刀数学模型。基于数学模型将铣刀切削刃离散成斜角切削单元,根据剪切区应力、应变和温度控制方程,由材料本构方程计算流动应力,通过坐标变换关系建立铣削力预测模型。得到的铣削力与已有铣削试验数据一致,验证了铣削力模型的有效性。     

Study on the influence of meso-geometrical features on milling force in precision machining of titanium alloy

Titanium Alloy is a typical material difficult to be processed for its characteristics of low thermal conductivity, and high chemical activity, which result in tool wear and the poor quality of the machined surface. In order to solve the problems existing in the processing of Titanium Alloy, considering the tool edge, micro-texture is implanted into the cemented carbide ball end milling cutter. The article analyzes the influence law of micro-texture and the tool edge radius of ball end milling cutter on mechanical properties of Titanium Alloy, establishes and verifies a mechanical predictive model of milling Titanium Alloy with ball end milling cutter surface based on the effect of micro-texture and the tool edge. Finally, with regard to the minimum cutting force as the target, the article uses genetic algorithm to optimize meso-geometrical features parameters of the cemented carbide ball end milling cutter. The article also provides the foundation for efficient and high-quality processing of Titanium Alloy.