CN110253066B - Top cutter identification and elimination method for five-axis plunge milling of integral impeller - Google Patents

Top cutter identification and elimination method for five-axis plunge milling of integral impeller Download PDF

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CN110253066B
CN110253066B CN201910356878.1A CN201910356878A CN110253066B CN 110253066 B CN110253066 B CN 110253066B CN 201910356878 A CN201910356878 A CN 201910356878A CN 110253066 B CN110253066 B CN 110253066B
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魏兆成
王敏杰
李国彦
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Dalian University of Technology
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Abstract

The invention provides a top cutter identification and removal method for five-axis plunge milling of an integral impeller, which comprises the following steps: s1, identifying the top knife: judging whether the bottom circles of the cutters of the two adjacent plunge mills intersect, and if so, determining that a cutter jacking phenomenon occurs; s2, selecting a rotation base point: two intersection points are formed on an extension surface of a ruled surface formed by the bottom circle of the ith plunge milling cutter and the axis of the whole row of cutters, and the intersection point far away from the intersection line is selected as a rotation base point; s3, top knife exclusion: obtaining new tool axis and tool location point through rotation, and S4, top tool detection: returning to the step S1, calculating whether the top knife phenomenon exists, and if so, repeating the steps S2 and S3 until the top knife phenomenon is eliminated. According to the top cutter identification and elimination method for five-axis plunge milling of the integral impeller, the problem of plunge milling top cutters is eliminated by adjusting the cutter shaft vectors and the cutter location points, processing abnormalities such as overload and vibration caused by plunge milling top cutters are avoided, the efficiency of plunge milling is guaranteed, and the efficiency of subsequent processing is not influenced.

Description

Top cutter identification and elimination method for five-axis plunge milling of integral impeller
Technical Field
The invention relates to the field of plunge milling of an integral impeller, in particular to a top cutter identification and elimination method in five-axis plunge milling trajectory planning.
Background
The plunge milling method is also called as a Z-axis milling method, the cutting efficiency is 4-5 times higher than that of the traditional milling method, and the plunge milling method has the advantage in the aspect of large removal rate of materials difficult to cut. The plunge milling is fed along the axial direction of the cutter, has the characteristics of small radial cutting force, good cutting stability, allowance of adopting a cutter with a large length-diameter ratio and the like, and is very suitable for rough machining of deep cavity and deep groove parts. Plunge milling is a cutting machining method with high material removal efficiency at present, and machining time can be obviously shortened. At present, a triaxial plunge milling module is already standard configuration of mainstream CAM software, is increasingly applied to the fields of die manufacturing, aerospace structural member processing and the like, and achieves a good application effect. However, due to the existence of the plunge milling top cutter problem, the application of the plunge milling technology in five-axis machining is restricted.
In the plunge milling process, when a top cutter problem exists, the machined surface of a workpiece often has large-area interference between the tool end face trace of the plunge milling of the current cutter and the tool end face trace of the plunge milling of the previous cutter. Leading to a sudden increase in the radial cutting depth of the current machining, a momentary doubling of the cutting load, causing overload or large cutting vibrations. In the existing machining simulation technology, the plunge milling top cutter is not over-cut or collision interference and cannot be automatically identified by the existing CAM and machining simulation software.
The problem of plunge milling of the top cutter has been studied, which is to avoid plunge milling of the top cutter by gradually reducing the plunge milling depth. The fact that the plunge milling depth is gradually reduced leads to the fact that the plunge milling depth is reduced in subsequent machining, more cutting allowance is left in the subsequent machining, and the efficiency of semi-finishing is affected. For three-axis machining, residual materials due to gradual reduction of plunge milling depth can be quickly removed through a face milling method, but for five-axis machining of the integral impeller, if a top cutter is removed through the gradual reduction of plunge milling depth, residual workpiece materials on the hub face can only be removed through a point milling method, and the efficiency of semi-finishing is seriously affected.
Disclosure of Invention
According to the technical problem that the machining efficiency is greatly influenced by the existence of the plunge milling top cutter, the top cutter identification and elimination method for five-axis plunge milling of the integral impeller is provided. The invention mainly utilizes the position of the top cutter to eliminate the phenomenon of top cutter by adjusting the cutter shaft vector and the cutter location point, thereby greatly improving the rough machining efficiency.
The technical means adopted by the invention are as follows:
a top cutter identification and removal method for five-axis plunge milling of an integral impeller comprises the following steps:
s1, identifying the top knife:
according to the track data of the existing conventional five-axis plunge milling cutter, a top cutter identification model is established, the relative position relation of bottom circles of adjacent plunge milling cutters when plunge milling is carried out to the bottom of a workpiece is analyzed, whether the bottom circles of the cutters of the adjacent plunge milling two times are intersected or not is judged, and if the bottom circles of the cutters of the adjacent plunge milling two times are intersected, the top cutter phenomenon is considered to occur.
S2, selecting a rotation base point:
and for the position with the cutter jacking phenomenon, jacking the cutter in the ith plunge milling, adjusting the cutter shaft vector and the cutter point of the ith plunge milling cutter, wherein two intersection points are formed on the extended surface of the ruled surface formed by the bottom circle of the ith plunge milling cutter and the axis of the whole row of cutters, and the intersection point far away from the intersection line is selected as a rotation base point.
S3, top knife exclusion:
the parameter of the axial line of the ith plunge milling cutter is u, the adjusting angle is offset surface crest line parameter u-delta u, delta u is 0.001, the connecting line of the position of the crest line parameter u on the offset ruled surface and the center of the bottom circle of the ith plunge milling cutter is L1, the connecting line of the position of the crest line parameter u-delta u on the offset ruled surface and the center of the bottom circle of the ith plunge milling cutter is L2, and the included angle from L1 to L2 is L2
Figure BDA0002045703910000021
Rotating the circle center of the bottom of the ith plunge milling cutter in a plane where the circle center of the bottom of the plunge milling cutter, a parameter point u of a top line of a leaf of an offset ruled surface and the parameter point u-delta u are located, rotating the circle center of the bottom of the ith plunge milling cutter around a rotation base point with the radius of the plunge milling cutter being R, and rotating the circle center of the bottom of the ith plunge milling cutter around the radius of R in the direction of u → u-delta u, namely, rotating and moving an AOu broken line segment around the rotation base point with the parameter position u to u-delta u, wherein the new position to which the circle center O of the bottom of the ith plunge milling cutter is moved is a new tool position O1 of the ith plunge milling, and the connecting line of the u-delta u and the new tool position.
S4, top knife detection:
returning to the step S1, calculating whether the top cutting phenomenon exists, if so, repeating the steps S2 and S3, and continuing to obtain a new cutter axis and a new cutter location point through rotation until the top cutting phenomenon is eliminated.
Further, in step S1, in the top tool identification process, in the top tool identification model, a distance from an intersection line of planes of the ith-1 th plunge milling cutter and the ith plunge milling cutter bottom circle to the ith plunge milling cutter bottom circle center O is calculated, and if the distance is smaller than the radius R of the plunge milling cutter, it is determined that there is a top tool phenomenon in two adjacent plunge milling.
Further, in step S2, the tool axis is obtained from a ruled surface with a blade profile normal offset, a blade vertex line and a blade root line of the offset surface are parameterized, a parameter value is [0, 1], and the tool axis is obtained by connecting corresponding parameter points of the blade vertex line and the blade root line.
Compared with the prior art, the top cutter identification and elimination method for five-axis plunge milling of the integral impeller judges whether bottom circles of cutters of two adjacent plunge mills intersect, if so, the top cutter phenomenon is considered to occur, the top cutter phenomenon is eliminated by adjusting cutter shafts and cutter positions of the top cutters, automatic planning of cutter tracks before five-axis plunge milling rough machining can be achieved, rough machining efficiency can be greatly improved, the cutter tracks without top cutters and interference can be directly generated by compiling software, track planning efficiency is improved by over 80%, and the top cutter identification and elimination method is used in five-axis plunge milling track planning of the integral impeller.
The top cutter identification and elimination method for five-axis plunge milling of the integral impeller is based on a double-row slotting plunge milling process, and optimizes and solves the potential top cutter problem in cutter path planning of the process.
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In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
FIG. 1 is a plunge milling top tool identification model according to the present invention.
FIG. 2 is a schematic view of the present invention excluding a plunge milling top tool.
Fig. 3 is a schematic view illustrating the adjustment of the knife shaft according to the present invention.
Fig. 4 is a view of the present invention with the top knife removed by a rotating knife shaft.
FIG. 5 is a schematic diagram of a tool path before removal of a plunge milling top cutter according to the present invention.
FIG. 6 is a schematic diagram of the tool path after the top plunge milling cutter is removed.
FIG. 7 is a diagram showing the effect of plunge milling of the whole impeller after the top cutter is removed.
Detailed Description
As shown in the figure, the invention provides a top cutter identification and elimination method for five-axis plunge milling of an integral impeller, which comprises the following steps:
s1, identifying the top knife:
establishing a top cutter identification model according to the track data of the existing conventional five-axis plunge milling cutter, analyzing the relative position relation of bottom circles of adjacent plunge milling cutters when plunge milling is carried out on the bottom of a workpiece as shown in figure 1, judging whether the bottom circles of the cutters of two adjacent plunge milling are intersected or not, and considering that the top cutter phenomenon occurs if the bottom circles of the cutters of two adjacent plunge milling are intersected; in the specific identification process of top cutter identification, in a top cutter identification model, calculating the distance from the intersection line of the planes of the bottom circles of the ith plunge milling cutter and the ith plunge milling cutter to the circle center O of the bottom of the ith plunge milling cutter, and if the distance is smaller than the radius R of the plunge milling cutter, considering that the top cutter phenomenon exists in the adjacent plunge milling.
S2, selecting a rotation base point:
for the position with the cutter jacking phenomenon, the cutter jacking occurs in the ith plunge milling, through the adjustment of the cutter shaft vector and the cutter location point of the ith plunge milling cutter, two intersection points are formed on the extended surface of the ruled surface formed by the bottom circle of the ith plunge milling cutter and the axis of the whole row of cutters, and the intersection point far away from the intersection line is selected as a rotation base point, as shown in fig. 3; the cutter axis is obtained by a ruled surface with a blade profile surface normal offset, a blade top line and a blade root line of the offset surface are parameterized, the parameter value is [0, 1], and the cutter axis is obtained by connecting corresponding parameter points of the blade top line and the blade root line.
S3, top knife exclusion:
the parameter of the axial line of the ith plunge milling cutter is u, the adjusting angle is offset surface crest line parameter u-delta u, delta u is 0.001, the connecting line of the position of the crest line parameter u on the offset ruled surface and the center of the bottom circle of the ith plunge milling cutter is L1, the connecting line of the position of the crest line parameter u-delta u on the offset ruled surface and the center of the bottom circle of the ith plunge milling cutter is L2, and the included angle from L1 to L2 is L2
Figure BDA0002045703910000041
Rotating the bottom circle center of the ith plunge milling cutter in a plane where the bottom circle center of the plunge milling cutter and the parameter point u-delta u of the offset ruled surface leaf crest line are located, and performing plunge milling on the bottom circle center of the ith plunge milling cutterAnd rotating in the direction of u → u-delta u by taking R as a radius around a rotation base point, namely rotating an AOu broken line segment around the rotation base point, wherein as shown in fig. 3 and 4, the parameter position u is rotated to u-delta u, and the new position to which the circle center O of the bottom of the ith plunge milling cutter is moved is the new tool position O1 of the ith plunge milling, and the connecting line of the u-delta u and the new tool position O1 is used as the tool axis of the ith plunge milling.
S4, top knife detection:
returning to the step S1, calculating whether the top cutting phenomenon exists, if so, repeating the steps S2 and S3, and continuing to obtain a new tool axis and a new tool location point through rotation until the top cutting phenomenon is eliminated, as shown in fig. 2.
The top cutter identification and elimination method for the five-axis plunge milling of the integral impeller can be used for inspecting and optimizing a preliminarily planned five-axis plunge milling processing track, namely, pre-identifying the cutter track of the five-axis plunge milling processing before processing and judging whether the top cutter occurs. If the top cutter occurs, the top cutter is eliminated by adopting a cutter shaft vector adjustment method. The method can greatly save the design time and energy of designers, improve the efficiency, ensure the accuracy, prevent the generation of a cutter jacking phenomenon in the machining process and prevent the damage to a cutter, a workpiece and a machine tool, and is a cutter jacking identification and removal method in the five-axis plunge milling trajectory planning.
The invention discloses a top cutter identification and elimination method for five-axis plunge milling of an integral impeller, and relates to cutter path planning of five-axis plunge milling of the integral impeller.
According to the top cutter identification and elimination method for five-axis plunge milling of the integral impeller, the problem of plunge milling top cutters is eliminated by adjusting the cutter shaft vectors and the cutter location points, processing abnormalities such as overload and vibration caused by plunge milling top cutters are avoided, the efficiency of plunge milling is guaranteed, and the efficiency of subsequent processing is not influenced.
Example 1
As shown in fig. 1 to 7, the invention provides a top cutter identification and elimination method for five-axis plunge milling of an integral impeller, which specifically comprises the following steps:
step 1: in the five-axis plunge milling process, the bottom end of the cutter of adjacent plunge milling twice is marked as Oi-1、OiThe former plunge milling is marked as a cutter shaft i-1, and the latter plunge milling is the cutter shaft i, as shown in fig. 1. When the top cutter of plunge milling occurs, the bottom circle O of the milling cutter of the cutter shaft iiIs not completely at the bottom of the cutter shaft i-1i-1Contact with the unprocessed region of the cutter shaft i-1 means the ith cutter bottom circle O in plunge milling1With the bottom circle O of the i-1 st knifeiAnd (4) intersecting.
Therefore, the identification model of the five-axis plunge milling top cutter is defined as follows: bottom circle O of the i-1 st knifei-1The plane is alpha, the bottom circle O of the (i-1) th knifei-1The plane is alpha, the ith knife bottom circle OiThe plane is beta. The two planes intersect to obtain an intersection line L1，OiTo a straight line L1Is d, if d<And R, considering that top cutting occurs.
Step 2: selecting a rotation base point of a cutter shaft vector, and based on the established five-axis plunge milling top cutter semi-analytic identification model, determining a rotation base point A at the bottom of the ith plunge milling cutter in the top cutter situation, rotating a certain angle around the rotation base point A in the direction away from the bottom of the ith-1 plunge milling cutter, wherein the bottom circle of the ith plunge milling cutter is above the plane alpha of the bottom of the ith-1 plunge milling cutter, and the intersection line of the plane of the bottom of the ith plunge milling cutter and the plane of the bottom of the ith-1 plunge milling cutter is far from the circle center OiIs greater than the radius of the plunge cutter, it is assumed that no top cutting occurs in the adjusted ith plunge milling process, as shown in fig. 2.
And step 3: when the numerical control plunge milling machining track is adjusted to remove the top cutter, the rotation base point A is selected as shown in figure 3, the offset ruled surface and the circular curve at the bottom of the plunge milling cutter have two intersection points, the intersection point far away from the intersection line is selected from the two intersection points as the rotation base point A, the circle center point at the bottom of the plunge milling cutter is marked as C, and the symmetrical point of the point A on the circle at the bottom of the cutter is Bi(XBi,YBi,ZBi)。
The parameter node of the offset ruled surface corresponding to the cutter axis of the currently generated plunge milling top cutter is recorded as u1As shown in FIG. 4The axis and the point of the cutter are rotated by taking the point A as a rotation base point, and a parameter point u is arranged on a cover disc line of the offset ruled surface1Starting point is uiCi(i ═ 1,2,3, …, n-1) and ui+1Ci(i-1, 2,3, …, n-1) angle
Figure BDA0002045703910000061
In order to rotate at a rotation angle, Δ u is 0.001 in the present embodiment, and a new circle center at the bottom of the plunge milling cutter is obtained after rotation and is marked as Ci+1Recording the center of a circle at the bottom of the new plunge milling cutter as C according to the rotation base point Ai+1Calculating a rotation base point A and recording the rotation base point A as C about the center of a circle at the bottom of a new plunge milling cutteri+1Point of symmetry Bi+1(i ═ 1,2,3, …, n-1), comparison Bi+1Point Z coordinate value and Ci+1Z coordinate value of point, if Bi+1Point Z coordinate value greater than Ci+1Stopping rotating the Z coordinate value of the point, and recording the circle center of the bottom of the new plunge milling cutter as Ci+1I.e. the final tool location point, u, of the parameter pointi+1Ci+1The straight line is the axis of the plunge milling cutter corresponding to the parameter point. If B isi+1Point Z coordinate value less than Ci+1The Z coordinate value of the point continues to rotate around the rotation base point A until Bi+1Point Z coordinate value greater than Ci+1And (3) eliminating the top cutter phenomenon by using the Z coordinate value of the point. The tool path before plunge top exclusion is schematically shown in fig. 5, and the tool path after plunge top exclusion and the machined toolmarks are shown in fig. 6 and 7.
The embodiment provides a method for identifying and removing a top cutter in five-axis plunge milling based on a 'double-row slotting' plunge milling method, can solve the potential top cutter problem in the plunge milling process, can automatically identify a top cutter area in a track and can remove the top cutter phenomenon by adjusting a cutter shaft vector. The defects that the cutter track needs manual debugging, the efficiency is low, and time and labor are wasted in the conventional plunge milling rough machining of the impeller are overcome. The method of the invention can be programmed into software to directly generate the cutter track without top cutter and interference, and the efficiency is improved by more than 80%.
The invention provides a method for eliminating a top cutter of plunge milling through cutter shaft vector adjustment aiming at five-axis plunge milling of an integral impeller. The method can effectively eliminate the plunge milling top cutter, and does not influence the efficiency of subsequent processing while ensuring the high efficiency of plunge milling processing.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.

Claims (3)

1. A top cutter identification and removal method for five-axis plunge milling of an integral impeller is characterized by comprising the following steps:
s1, identifying the top knife:
establishing a top cutter identification model according to the track data of the existing conventional five-axis plunge milling cutter, analyzing the relative position relation of bottom circles of adjacent plunge milling cutters when plunge milling is carried out on the bottom of a workpiece, judging whether the bottom circles of the cutters of the adjacent two plunge milling are intersected or not, and considering that the top cutter phenomenon occurs if the bottom circles of the cutters of the adjacent two plunge milling are intersected;
s2, selecting a rotation base point:
for the position with the cutter jacking phenomenon, when the cutter jacking occurs in the secondary plunge milling, by adjusting the cutter shaft vector and the cutter location point of the secondary plunge milling cutter, the extending surface of the ruled surface formed by the bottom circle of the secondary plunge milling cutter and the axis of the whole row of cutters has two intersection points, and an intersection point A far away from an intersection line is selected as a rotation base point, wherein the intersection line is the intersection line of the bottom circle of the secondary plunge milling cutter and the bottom circle of the previous plunge milling cutter;
s3, top knife removal and top knife detection:
the parameter node of the offset ruled surface corresponding to the cutter axis of the currently generated plunge milling top cutter is recorded as u1The cutter axis and the cutter point take the point A as a rotation base point, and a parameter point u is taken as a parameter point on a cover disc line of the offset ruled surface1Starting point is uiCiAnd ui+1CiAngle phi ofiRotate for a rotation angle, i =1,2,3 … n-1, parameter point ui+1Is ui-u, < u =0.001, and the point of symmetry of point a on the bottom circle of the tool is designated BiThe circle center of the bottom of the plunge milling cutter is marked as CiAnd the circle center at the bottom of the new plunge milling cutter is recorded as C after rotationi+1According to the rotation base point A and the new circle center C at the bottom of the plunge milling cutteri+1Calculating the rotation base point A about the bottom circle center C of a new plunge milling cutteri+1Point of symmetry Bi+1Comparison Bi+1Point Z coordinate value and Ci+1Z coordinate value of point, if Bi+1Point Z coordinate value greater than Ci+1The Z coordinate value of the point stops rotating, and the center of the circle C at the bottom of the new plunge milling cutteri+1I.e. the final tool location point, u, of the parameter pointi+1Ci+1The straight line is the axis of the plunge milling cutter corresponding to the parameter point; if B isi+1Point Z coordinate value less than Ci+1The Z coordinate value of the point continues to rotate around the rotation base point A until Bi+1Point Z coordinate value greater than Ci+1And (3) eliminating the top cutter phenomenon by using the Z coordinate value of the point.
2. The method for identifying and eliminating the top cutter in the five-axis plunge milling process of the integral impeller according to claim 1,
in step S1, in the top tool identification model, the specific identification process of the top tool identification calculates the distance from the intersection line of the planes of the bottom circles of the previous plunge milling tool and the current plunge milling tool to the center of the bottom circle of the current plunge milling tool, and if the distance is smaller than the radius R of the plunge milling tool, it is determined that there is a top tool phenomenon in the two adjacent plunge milling tools.
3. The method for identifying and eliminating the top cutter in the five-axis plunge milling process of the integral impeller according to claim 1,
in step S2, the tool axis is obtained from the ruled surface of the blade profile with normal offset, the blade top line and the blade root line of the offset surface are parameterized, the parameter value is [0, 1], and the tool axis is obtained by connecting the corresponding parameter points of the blade top line and the blade root line.
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