球头铣刀刀具磨损建模与误差补偿

针对刀具磨损度量方式和模型建立的问题,以球头刀具为研究对象,提出球头铣刀刀具磨损的度量方式,建立球头刀具磨损模型.以复映磨损在硬度较软加工材料上的方式测量球头刀具磨损,确定刀具磨损模型系数,给出刀具磨损模型系数确定的具体实现方法.加工试验验证球头刀具磨损度量方式的合理性和所建立刀具磨损模型的正确性,同时针对数控铣削加工中球头铣刀刀具磨损引起的误差提出离线仿真误差补偿算法,给出离线仿真误差补偿算法的具体实现步骤,通过建立的刀具磨损引起的加工误差模型仿真获得加工走刀步的误差.对于误差超差的走刀步,预先修改数控加工(Numerical control,NC)程序,保证实际加工零件满足精度要求.误差补偿验证试验表明所提出的离线仿真误差补偿算法的正确性和有效性.

Modeling and Wear-induced Error Compensation of Ball-end Milling Cutter Wear

The measure mode of wear is proposed for ball-end milling cutter and tool wear model is built. Tool wear model coeffi-cients are decided to use tool wear data measured by mapping mode in ball-end milling cutter. Various experimental works have been performed to verify the validity of the proposed tool wear model. It is shown that the proposed model is capable of accurate prediction tool wear of ball-end milling cutter. At the same time, the algorithm of off-line simulation error compensation is proposed for wear-induced error of ball-end milling cutter. The algorithm predicts the machining error for one tool move using the proposed tool wear model in the NC mill machining and acquires one tool move of over tolerance. The NC programs are modified prior to practical machining operations for one tool move of over tolerance. The error compensation experimental results verify the validity of the proposed algorithm of off-line simulation error compensation and show that the error compensation algorithm is satisfying.