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工程设计学报
Chinese Journal of Engineering Design  2011, Vol. 18 Issue (2): 98-102    DOI:
    
Modeling and analysis for virtual five-axis flank milling process
 ZHANG  Li-Qiang1, WANG  Yu-Han2
1. College of Mechanical Engineering, Shanghai University of Engineering Science, Shanghai 201620, China;
2. School of Mechanical Engineering, Shanghai Jiaotong University, Shanghai 200240, China
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Abstract  A complete geometric and force model for five-axis flank milling was presented, and then geometric simulation and cutting forces prediction can be conducted based on the integrated model. Feedrate scheduling was planned based on the mechanistic model. The method selected for geometric stock modeling was the dexel approach. The cutter workpiece engagements defined the instantaneous intersection boundary between the cutting tool and the in-process workpiece. From the CWE, the cutter entry-exit angles and depth of cuts were found and used to calculate the instaneous cutting forces. The constrained optimization was solved by sequential quadratic programming and the machine was operated at threshold levels. The process was optimized by varying the feed as the tool-workpiece engagements vary along the tool path, and the research provided a powerful tool for analysing five\|axis flank milling. Production time in flank milling dual blades was reduced considerably to 40% with the satisfaction of precision demands．

Key words： five-axis      flank milling      geometric simulation      mechanistic model     
Published: 28 April 2011
CLC:  TG 506  
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ZHANG Li-Qiang, WANG Yu-Han. Modeling and analysis for virtual five-axis flank milling process. Chinese Journal of Engineering Design, 2011, 18(2): 98-102.

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https://www.zjujournals.com/gcsjxb/     OR     https://www.zjujournals.com/gcsjxb/Y2011/V18/I2/98


虚拟五轴侧铣加工过程建模与仿真分析

提出一种面向五轴侧铣加工的球头刀几何与力学模型,利用该综合模型可对复杂曲面加工进行几何仿真与切削力预测,对加工过程进行速度规划．切削工件几何模型采用深度元素法,通过与刀具模型之间的布尔操作实现材料去除过程,通过分析刀具与工件接触区域,得到刀具在不同瞬时的轴向范围及沿轴向各微元的切入角和切出角,转换为铣削力模型所需的几何信息．采用序列二次规划法优化进给速度,使机床工作在多个约束条件的最大潜能值内．整个规划过程随刀具与工件接触区域的变化而不断优化,研究工作为五轴侧铣加工过程提供了有力的分析工具．双叶片五轴侧铣加工仿真实验表明,在满足叶片精度条件下,采用优化进给速度可使零件加工效率提高约40%．

关键词： 五轴,  侧铣,  几何仿真,  力学模型 
[1] HE Gai-yun, PANG Kai-rui, SANG Yi-cun, LIU Chen-hui, WANG Hong-liang. Application of surface matching method in tool path optimization[J]. Chinese Journal of Engineering Design, 2019, 26(2): 190-196.