CN110888394A - Cutter shaft optimization method for wear control of curved surface numerical control machining ball end mill - Google Patents
Cutter shaft optimization method for wear control of curved surface numerical control machining ball end mill Download PDFInfo
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Abstract
The invention provides a cutter shaft optimization method for wear control of a curved surface numerical control machining ball-end milling cutter, which comprises the steps of firstly constructing a cutter-workpiece meshing area at each cutter position according to an input cutter path and geometric information, and solving a non-interference cutter shaft space at each cutter position; then dividing a cutting edge of the cutter into a plurality of cutting sections along the axial direction of the cutter, calculating the cutting length of each cutting section of the cutter at each cutter position under an initial cutter shaft according to the obtained cutter-workpiece meshing area so as to obtain the cutting length of the cutter for processing the whole part in each cutting section, and calculating the cutter abrasion loss of each cutting section according to the abrasion rate; and finally, solving the cutter shaft direction in which the cutter wear is uniformly distributed in each cutting interval of the cutter edge from the non-interference cutter shaft space of each cutter point by adopting a fixed cutter shaft strategy. The cutter shaft adjusting device is high in practicability and operability, cutter abrasion is uniformly distributed by adjusting the cutter shaft, and the problem that the cutter is too fast to lose efficacy due to the fact that the cutter abrasion is concentrated in a local area can be effectively solved.
Description
Technical Field
The invention relates to a CAD/CAM technology, in particular to a multi-axis numerical control machining technology of a free curved surface, and specifically relates to a cutter shaft optimization method for wear control of a curved surface numerical control machining ball-end milling cutter.
Background
High-end equipment such as aviation, aerospace and ships and the like are made of titanium alloy, nickel-based high-temperature alloy and other difficult-to-machine materials in a large quantity, and parts made of the materials are extremely easy to wear in the machining process, so that the manufacturing cost is increased, and the final surface quality of the parts is seriously affected. In addition, parts such as an aircraft engine blade disc, a casing and the like usually have complex structures and curved surfaces, the numerical control programming difficulty is high, in order to save the process preparation time in the actual production, small-size ball-head cutters are usually adopted for dead axle milling, the cutter abrasion is often concentrated on local cutting edges, the service life of the cutter is greatly shortened, frequent cutter changing is caused, the machining efficiency is low, and the quality stability is poor.
Aiming at cutter wear control, patent 201510844565.2 discloses a novel composite material hole making cutter, the cutting part of the cutter consists of a twist drill, a sawtooth reamer, a reamer and an artificial carborundum grinding body, and the technical problems of cutter wear, poor drilling quality and the like in the drilling process of carbon fiber composite materials can be solved; patent 201810066761.5 discloses a parameter optimization method for cooling and lubricating process during minimal quantity lubrication cutting, which establishes an optimization function according to the characteristics of minimal quantity lubrication machining, obtains an optimal parameter combination through a machine learning algorithm, and can effectively improve cutting performance, control cutter abrasion and improve surface quality.
The existing method respectively optimizes the cutter design and the cooling and lubricating mode to prolong the service life of the cutter, and does not consider the idea of uniformly distributing the cutter abrasion by optimizing the cutter shaft direction.
Disclosure of Invention
The invention aims to solve the problem that the wear area of the cutting edge of a ball head cutter is concentrated under the existing multi-axis machining method, so that the cutter is too fast to lose efficacy, and provides a cutter shaft optimization method for wear control of a curved surface numerical control machining ball head milling cutter, wherein the cutter shaft is adjusted to ensure that the cutter wear is uniformly distributed on the cutting edge, so that the actual service life of the cutter is prolonged, the efficiency is improved, and the machining quality is ensured, and the method specifically comprises the following steps: comprises that
The method comprises the following steps: calculating the tool-workpiece engagement area at all tool positions; extracting the generated tool pathInformation, sorting the cutter position points according to the processing sequence to obtain a point set P ═ { P ═ Pt＝(xt，yt，zt，it，jt，kt) 1., n }, where (x) is equal tot，yt，zt) Is the position vector of the knife position point, (i)t，jt，kt) And constructing a set Pa ═ Pa of adjacent cutter point pairs for cutter shaft vectors corresponding to the cutter point pairs and n is the total number of the cutter point pairst＝(pt，pt+1)|t＝1，...，n-1；pt，pt+1E.g. P }, constructing a geometric body T of the ball-point cutter according to the cutter radius, and traversing Pa in sequence1、Pa2… … until all the point pairs are obtained, the tool-workpiece engagement region of the surface of the tool geometry T tangent to the engagement region entity is calculated in turn, and the obtained tool-workpiece engagement region at all the tool positions is CWE ═ { CWE [ CWE ]t|t＝1，...，n}；
Step two, calculating the non-interference cutter shaft space at all cutter positions;
calculating the distance between any cutter shaft vector and a discrete point of a part blank, and removing the cutter shaft vector from an initial cutter shaft space when the distance is less than or equal to the radius R of a cutter; otherwise, the cutter shaft is a feasible cutter shaft; sequentially carrying out interference detection on the cutter shaft vectors to be detected, extracting a non-interference cutter shaft space from the initial cutter shaft space, and obtaining a point ptWithout interference arbor space TSt＝{(iv，jv，kv) And repeating the steps until the interference-free cutter shaft space TS (transport stream) at the n cutter positions is obtained through traversal, wherein V is the number of the interference-free cutter shafts at the point, and the step is repeated until the interference-free cutter shaft space TS at the n cutter positions is obtained through traversalt|t＝1，...，n}；
Step three, calculating the cutter abrasion loss under the given cutter shaft;
equally dividing the cutting edge of the tool into a plurality of cutting sections CR ═ CR along the axial direction of the toolsAnd l S is the number of cutting intervals, the tool wear distribution of each tool position pair is calculated, and all CR after the complete part is machined are obtained by superpositionsCorresponding wear amount W ═ Ws1., S }; if in the current point pairThe first point is the last point of one tool path, the second point is the initial point of the next tool path, and the tool abrasion loss is not calculated under the condition;
step four, cutter shaft optimization;
for tool track TpuAnd (U is 1, U), wherein U is the number of tool paths, the intersection of all tool position point interference-free tool shaft spaces of the tool paths is solved to obtain a common interference-free tool shaft space, a tool shaft is optimized based on a genetic algorithm, the cutting length, the abrasion loss and the abrasion loss variance of S cutting intervals under the tool path combination are calculated according to the third step, and finally the optimal tool shaft combination is output.
As an improvement, if the first point in the current point pair is the starting point of one tool path, according to Pa1The processing method of (1) calculating the tool-workpiece engagement area, solving the blank removal body and updating the blank state.
As an improvement, Pa1The processing method comprises the following steps: constructing a ball nose tool geometry T according to the tool radius, at p1Performing Boolean intersection operation on the T and the part blank to obtain p1The surface of the tool-workpiece meshing area solid where the tool geometric body T is tangent to the meshing area solid is p1Tool-workpiece engagement area CWE of1And constructing a CWE1Point set of
E is a region CWE1The number of discrete points; at the same time, for Pa1Interpolating the cutter axis vectors of the two cutter location points, dispersing the cutter geometry T into point cloud to construct a cutter swept volume TS1And to TS1Performing Boolean intersection operation with the blank, and deleting the intersection part from the blank to obtain the update state R of the blank1The intersecting part is defined as a blank removing body Tb1。
As an improvement, if the first point in the current point pair is the last point of one tool path and the second point is the starting point of the next tool path, the boolean intersection operation is only needed to be performed on the T at the first point and the previous blank removal body, the tangent surface of the T and the blank removal body is calculated, the calculated surface is the tool-workpiece engagement area at the first point, and at this time, the tool-workpiece engagement area at the first point is the surface of the tangent surface of the T and the blank removal bodyThe tool swept body between two points is not required to be constructed, the blank updating state is the same as that of the previous point pair, and the steps are repeated until all the point pairs in Pa are traversed to obtain the tool-workpiece meshing area CWE (CWE) of all the tool positionst|t＝1，...，n}。
As an improvement, for Pa2Calculating T at p2Is and Tb1Tangential surface, obtaining a surface p2Tool-workpiece engagement area CWE of2And constructing a CWE2Point set of
Calculating TS according to the same method2Then through the current blank R1Performing Boolean operation to obtain processed Pa2Rear blank R2，TS2And R1The crossed part is a blank removing body Tb2(ii) a Repeating pairs Pa for subsequent pairs of tool sites2The blank removing body is solved, the tool-workpiece meshing area is calculated, the blank is updated, the steps are repeated until all the point pairs in Pa are traversed, and the tool-workpiece meshing areas CWE (CWE) at all the tool positions are obtainedt|t＝1，...，n}。
As an improvement, in step two, for the knife position point ptEstablishing a Gaussian sphere by taking the point as the center of the sphere, and dispersing the Gaussian sphere into a point set S ═ Sg＝(xg，yg，zg) 1.. G }, where G is the number of discrete points, then p istsgInitial arbor space of this point, ptsgA point b (x (m), y (m), z (m)) between, m > 0, satisfying:
according to the updated blank Rt-1And constructing point cloud model to obtain point set
O is
The number of the points is such that,and satisfy rpob⊥ptsgObtaining rpoThe distance to point b is shown as
As an improvement, in the third step, the distance range [ l ] from each section to the cutter shaft is calculatedmin，lmax](ii) a Set point pair PatAccording to the CWE obtained in the step onetPoint set
The distance from the cutter shaft to the cutter shaft judges which cutting intervals participate in the cutting of the section; wherein the arc length corresponding to the two points at the farthest interval in the s-th interval is set as the cutting length l of the interval; at PatThe wear distance of the section s is obtained by the length d of the tool path between the tool contacts corresponding to the two points, wherein d can be approximate to the linear distance between the two tool contacts and the section CRsIs calculated by equation (2):
wherein d and l represent the machining point pair PatCorresponding tool path length and cutting length of section s, FzZ is the number of cutting edges for each tooth feed.
For the cutting edge portion of the ball nose tool, the cutting speed of the section s can be expressed by the formula (3):
wherein r' represents the average distance from the cutting section to the cutter shaft, and N is the main shaft rotating speed.
Calculating the wear rate of the cutter interval s by adopting a formula (4):
VB＝KVg aFz b(4)
wherein K is a service life coefficient, and a and b are coefficients of influence of cutting speed and feed quantity on the service life degree of the cutter;
then, according to the formulas (2) and (4), determining the abrasion loss w of the section s after the whole curved surface is processed, as shown in the formula (5): w ═ VBL (5)。
Wherein, L here is the wear distance of the section s after the whole curved surface is processed.
As an improvement, in the fourth step, the abrasion loss of S cutting intervals under the tool path combination is calculated according to the third step, reasonable initial parameters are set based on a genetic algorithm, after one-time selection, crossing and mutation operation is carried out, the abrasion loss value of each interval is recalculated, and the abrasion loss variance delta is calculated2The calculation is as shown in equation (6)
Wherein s is the number of cutting intervals,
the average value of the wear amounts of the S sections is shown.
As an improvement, the cutter shaft direction for fixing each cutter rail is set to be an angle theta, and the value of the angle theta is selected from the public non-interference cutter shaft space of each cutter rail and corresponds to different cutter shaft vectors.
As an improvement, the cutting length and the abrasion loss of each section are recalculated according to the step three according to the obtained CWE corresponding to the cutter shaft vectors of different theta angles, and then the abrasion loss variance delta under the new combination is calculated2And when the iteration times are reached, selecting the cutter shaft vector corresponding to the minimum variance combination as an optimal cutter shaft processing mode for processing the part.
Has the advantages that: the invention provides a cutter shaft optimization method for wear control of a curved surface numerical control machining ball-end milling cutter, which comprises the steps of firstly constructing a cutter-workpiece meshing area at each cutter position according to an input cutter path and cutter geometric information, and solving a non-interference cutter shaft space at each cutter position; then dividing a cutting edge of the cutter into a plurality of cutting sections along the axial direction of the cutter, calculating the cutting length of each cutting section of the cutter at each cutter position under an initial cutter shaft according to the obtained cutter-workpiece meshing area, further obtaining the cutting length of the cutter for processing the whole part in each cutting section, and calculating the cutter abrasion loss of each cutting section according to the abrasion rate; and finally, solving the cutter shaft direction which enables the cutter wear to be uniformly distributed in each cutting interval of the cutter edge from the non-interference cutter shaft space of each cutter point by adopting a fixed cutter shaft strategy and based on a genetic algorithm.
The cutter shaft adjusting device has strong practicability and high operability, cutter abrasion is uniformly distributed by adjusting the cutter shaft, the problem that the cutter is too fast to lose efficacy due to the fact that cutter abrasion is concentrated in a local area can be effectively solved, meanwhile, the abrasion area of the cutter is controlled from the source, cutter abrasion is uniformly generated on the cutting edge of the ball-end cutter, the machining quality and the geometric accuracy of a workpiece are guaranteed, the service life of the cutter is prolonged, and the use efficiency is improved to a certain extent.
Drawings
FIG. 1 is a schematic diagram of a surface designed to verify simulation effects.
FIG. 2 is a flow chart of a cutter shaft optimization method for wear control of a curved surface numerical control machining ball end mill.
FIG. 3 is a schematic diagram of the tool surface meshing of the present invention.
FIG. 4 is a schematic view of the swept volume of the tool of the present invention.
Fig. 5a) is a schematic view of initial arbor generation of the present invention, and fig. 5b) is a schematic view of arbor interference detection of the present invention.
Fig. 6 is a schematic view of the determination of the cutting zone of the present invention. In which fig. 6a) a schematic view of the cutting interval determination. Fig. 6b) cutting length determination schematic.
FIG. 7 is a graph showing the wear rate of each section of the cutting edge of the ball nose cutter.
Fig. 8 is a schematic illustration of the effect of a knife axis change on the area of the knife-workpiece engagement.
FIG. 9 is a schematic flow chart of the genetic algorithm of the present invention.
Fig. 10 is a graph comparing the conventional fixing process with the process result of the present invention.
Detailed Description
The effectiveness of the cutter shaft optimization method for wear control of the curved surface numerical control machining ball nose cutter is verified by combining the attached drawings, and related examples are designed for verification, and the constructed curved surface is shown in fig. 1. The workpiece is made of nickel-based high-temperature alloy. Other parameters in the experiment were as follows:
cutting tool: ball nose cutter, radius R12mm, 4 edge
Cutting depth dc：0.3mrn
Main shaft rotation speed N: 700rpm
Feed per tooth Fz：0.3mrn
The processing mode is as follows: straight milling
Tool wear threshold: 0.2mrn
A cutter shaft optimization method for wear control of a curved surface numerical control machining ball end mill comprises the following steps as shown in figure 2:
1) the tool-workpiece engagement area at all tool locations is calculated. Extracting information of a plurality of generated curved surfaces, for example, 105 tool tracks, and sorting 5248 tool positions according to the processing sequence to obtain a point set P ═ { P }t＝(xt，yt，zt，it，jt，kt) 1., n }, where (x) is equal tot，yt，zt) Is the position vector of the knife position point, (i)t，jt，kt) And n is the total number of the cutter positions. Constructing adjacent cutter point pairs Pa ═ Pat＝(pt，pt+1)|t＝1，...，n-1；pt∈P，pt+1∈P}。
The selected ball nose tool is gridded to form a tool geometry model T as shown in fig. 3. From Pa1At the beginning, at p1Performing Boolean operation on the T and the blank model B to obtain p1The entity of the tool-workpiece meshing area is obtained, and the entity of the meshing area to the tool position point p is obtained1At the nodes of the grid whose distance is the radius R of the tool, these points forming p1Tool-workpiece engagement area CWE of1The point set is
E is a region CWE1The number of discrete points.
Then to Pa1Interpolating the cutter axis vectors of the two cutter location points, dispersing the cutter geometric body T into point cloud to construct a cutter swept body model TS1As shown in FIG. 4, and for TS1Performing Boolean intersection operation with the blank, and deleting the intersection part from the blank to obtain the update state R of the blank1The intersecting part is defined as a blank removing body Tb1. For Pa2T is in p2Is and Tb1Tangential surface is p2Tool-workpiece engagement area CWE of2And constructing a CWE2Point set of
Calculating TS according to the same method2Then through the current blank R1Performing Boolean operation to obtain processed Pa2Rear blank R2，TS2And R1The crossed part is a blank removing body Tb2. Repeating pairs Pa for subsequent pairs of tool sites2The processing method of (1) is to find a blank removal body, calculate a tool-workpiece engagement area and update a blank. If the first point in the current point pair is the starting point of one tool path, according to Pa1Calculating a tool-workpiece meshing area by the processing mode, solving a blank removing body and updating a blank state; if the first point in the current point pair is the last point of one tool path and the second point is the starting point of the next tool path, the Boolean intersection operation is only needed to be carried out on the T at the first point and the previous blank removing body, the tangent surface of the T and the blank removing body is calculated, the calculated surface is the tool-workpiece meshing area at the first point, at the moment, a tool sweeping body between the two points does not need to be constructed, and the blank updating state is the same as that of the previous point pair. Repeating the steps until all the point pairs in Pa are traversed to obtain tool-workpiece engagement areas CWE (CWE) at all the tool positionst|t＝1，...，n}。
2) And calculating the non-interference cutter shaft space at all cutter positions. As shown in FIG. 5a, with a knife location point ptIs composed ofThe center establishes a Gaussian sphere and disperses the Gaussian sphere into a point set S ═ Sg＝(xg，yg，zg) 1.. G }, where G is the number of discrete points, then p istsgThe initial arbor space for that point. p is a radical oftsgA point b (x (m), y (m), z (m)) between, m > 0, satisfying the following formula:
detection of interference As shown in FIG. 5b, the determination of the renewed R blank according to step 1)t-1And constructing point cloud model to obtain point set
O is
Number of midpoints, rpoThe distance to point b is expressed as:
and satisfy rpob⊥ptsg。
The distance between any cutter shaft vector and the blank discrete point can be calculated according to the formula, if the distance is less than or equal to the radius R of the cutter, the cutter shaft vector can cause processing interference and is removed from the initial cutter shaft space; otherwise, the cutter shaft is a feasible cutter shaft. Interference detection is carried out on the cutter shaft vectors to be detected in sequence, and then the non-interference cutter shaft space can be extracted from the initial cutter shaft space. Thereby obtaining a point ptWithout interference arbor space TSt＝{(iv，jv，kv) And l V is 1, V, and V is the number of non-interference cutter shafts at the point. Repeating the steps until the interference-free cutter shaft space TS ═ TS of n cutter positions is obtained through traversalt|t＝1，...，n}。
3) And calculating the abrasion loss of the cutter under the given cutter shaft. Cutting section determination as shown in fig. 6a, the cutting edge of the tool is equally divided into 90 cutting sections CR ═ CR { CR ═ CR in the axial direction of the tools1, the length of S is the number of cutting sections, and the length range from the boundary of each section to the cutter shaft is calculated [ l [ S ] ]min，lmax]. For point pair PatTo find CWEtCorresponding point set
Distance to the knife axis andmin，lmax]and comparing to judge the cutting section where the point set is positioned. The cutting length of the s-th section is determined as shown in fig. 6b, and the arc length corresponding to the two points at the farthest intervals is the cutting length l of the section. At PatThe wear distance of the section s is obtained by the tool path length d between the tool contacts corresponding to the two points, and d can be approximate to the linear distance between the two tool contacts. Determining the machining time at the distance
The number of turns of the cutter between the two points is
From this, PatThe wear distance L in the inner interval s. The wear distance of the section s can be calculated by equation (2):
wherein d and l represent the machining point pair PatCorresponding tool path length and cutting length of section s, FzZ is the number of cutting edges for each tooth feed.
And the next step is to determine the abrasion loss of each cutting interval after the complete curved surface is processed according to the abrasion rate of the cutting edge. Firstly, the cutting speed of each section of the cutting edge needs to be obtained, and the formula is expressed as follows:
wherein r' represents the average distance from the cutting section to the cutter shaft, and N is the main shaft rotating speed.
And (3) calculating the wear rate of each section of the cutter by adopting a formula (4):
VB＝KVg aFz b(4)
where K is the life factor, which is related to the tool workpiece material and cutting conditions. a. And b is a coefficient of influence of the cutting speed and the feed quantity on the service life degree of the cutter, and can be obtained through a cutter service life experiment. The cutting speed and the feeding speed are used as variables, the machining time when the cutter reaches the set abrasion threshold value of 0.2mm is obtained through three groups of different experiments, and three coefficients are solved according to multiple regression analysis. The wear of 90 intervals under the selected work material is shown in fig. 7.
According to the formulas (2) and (4), the wear amount w of the section s after the whole curved surface is processed can be determined, as shown in the formula (5):
w＝VBL (5)
wherein, L here is the wear distance of the section s after the whole curved surface is processed.
If the first point in the current point pair is the last point of one tool path and the second point is the starting point of the next tool path, the tool wear amount is not calculated under the condition. Repeating the steps, calculating the cutter abrasion distribution of each cutter position pair, and overlapping to obtain all CR after the complete part is machinedsCorresponding wear amount W ═ Ws|s＝1，...，S}。
4) And (6) optimizing the cutter shaft. In order to ensure the smoothness requirement of adjacent cutter shafts, a fixed cutter shaft strategy is adopted, namely, when each cutter rail is processed, the direction of the cutter shaft is fixed, but different cutter rails can be processed by different cutter shafts. Based on the strategy, Tp is determined for any one tool pathuAnd (U ═ 1., U), wherein U is the number of tool paths, and the intersection of all tool positions of the tool paths without interference shaft spaces is calculated, so that the common non-interference shaft spaces of 105 tool paths are obtained. The cutter shaft direction of each cutter rail is respectively fixed to be different theta angles, and the value of the theta angle is selected from the public interference-free cutter shaft space of each cutter rail and corresponds to different cutter shaft vectors.
Calculating the abrasion loss of S cutting intervals under the tool path combination according to the step 3), setting related initial parameters by adopting a genetic algorithm for optimizing the cutter shaft, wherein in the designed example, the population scale is set to be 500, the maximum genetic algebra is 200, the binary length of the variable is 20, and the intersection probability and the variation probability are respectively 0.7 and 0.5.
After the initial population is subjected to one-time selection, crossing and variation operation, the abrasion quantity value of each interval is recalculated, and the abrasion quantity variance delta is calculated2As shown in equation (6).
Wherein the content of the first and second substances,
the average value of the wear amounts in 90 intervals.
As shown in fig. 8, in the process of machining the ball end mill, the change of θ does not change the size and direction of the CWE, but changes the cutting interval in which the ball end mill is located, so as to change the wear amount of each interval, and after adjusting the cutter shaft, the cutting length and the wear amount of each interval are recalculated according to the obtained CWE in step 3), and then the wear amount variance under the new combination is calculated. And when the iteration times are reached, selecting the cutter shaft vector corresponding to the variance minimum combination as an optimal cutter shaft processing mode for processing the part.
The specific steps of the genetic algorithm are as follows, and the flow chart of the genetic algorithm is shown in FIG. 9:
1) setting initial parameters including initial population scale p, maximum genetic algebra, crossover, mutation probability and the like, and initializing the population.
2) And calculating the abrasion magnitude value of each cutting interval through the population individuals, calculating the adaptability value according to the abrasion magnitude value, and evaluating the individuals through the adaptability.
3) And carrying out selection, crossing and mutation operations according to the individual fitness.
4) Calculating the abrasion loss value of the new individual again and calculating the variance, wherein gen is gen +1, if gen is less than or equal to MAXGN, jumping to the step 2, distributing the fitness value, and performing genetic operation again; if gen > MAXGN, the resulting individual with the greatest fitness is output as the optimal solution.
5) And decoding the optimal individual to obtain an optimal cutter shaft combination solution.
In order to clearly show the experimental result, a fixed cutter shaft machining mode is needed for comparison. In the fixed inclination angle processing, the included angle between the cutter shaft and the horizontal plane is fixed to be 90 degrees. The tool-workpiece engagement area in this manner is the same as that previously determined, and it is necessary to re-determine the CWE based on the determined CWEtCorresponding point set of
The distance to the cutter shaft is determined, the cutting interval is determined, the abrasion loss in the new cutting interval is calculated again, and the abrasion loss in 90 intervals is further obtained after 5248 cutter positions are machined.
The results of the wear calculation using the arbor processing method and the fixed inclination angle obtained by the present invention are shown in fig. 10, and it can be seen from the figure that when the fixed inclination angle of 90 ° is used for processing, the wear area of the tool is excessively concentrated near the 20 th interval, the maximum wear amount is 49 μm, and the other areas of the tool do not participate in the processing. After the cutter shaft generated by the invention is adopted to process the same curved surface, the cutter wear distribution is relatively uniform, the average wear loss is 15 micrometers, and the maximum wear loss is 25 micrometers at the position close to the cutter point. The wear area of the cutter is controlled from the source, so that the cutter is worn uniformly on the cutting edge of the ball-nose cutter, the processing quality and the geometric accuracy of a workpiece are ensured, the service life of the cutter is prolonged, and the service efficiency is improved to a certain extent.
The above-mentioned embodiments only express several embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.
Claims (10)
1. A cutter shaft optimization method for wear control of a curved surface numerical control machining ball end mill is characterized by comprising the following steps: comprises that
Step one, calculating cutter-workpiece meshing areas at all cutter positions; extracting the generated tool path information, and sequencing the tool position points according to the processing sequence to obtain a point set P ═ { P ═ Pt＝(xt，yt，zt，it，jt，kt) 1., n }, where (x) is equal tot，yt，zt) Is the position vector of the knife position point, (i)t，jt，kt) And constructing a set Pa ═ Pa of adjacent cutter point pairs for cutter shaft vectors corresponding to the cutter point pairs and n is the total number of the cutter point pairst＝(pt，pt+1)|t＝1，...，n-1；pt，pt+1E.g. P }, constructing a geometric body T of the ball-point cutter according to the cutter radius, and traversing Pa in sequence1、Pa2… … until all the point pairs are obtained, the tool-workpiece engagement region of the surface of the tool geometry T tangent to the engagement region entity is calculated in turn, and the obtained tool-workpiece engagement region at all the tool positions is CWE ═ { CWE [ CWE ]t|t＝1，...，n}；
Step two, calculating the non-interference cutter shaft space at all cutter positions;
calculating the distance between any cutter shaft vector and a discrete point of a part blank, and removing the cutter shaft vector from an initial cutter shaft space when the distance is less than or equal to the radius R of a cutter; otherwise, the cutter shaft is a feasible cutter shaft; sequentially carrying out interference detection on the cutter shaft vectors to be detected, extracting a non-interference cutter shaft space from the initial cutter shaft space, and obtaining a point ptWithout interference arbor space TSt＝{(iv，jv，kv) And repeating the steps until the interference-free cutter shaft space TS (transport stream) at the n cutter positions is obtained through traversal, wherein V is the number of the interference-free cutter shafts at the point, and the interference-free cutter shaft space TS is { TS ═ at the n cutter positionst|t＝1，...，n}；
Step three, calculating the cutter abrasion loss under the given cutter shaft;
equally dividing the cutting edge of the cutter along the axial direction of the cutterA plurality of cutting sections CR ═ CRsAnd l S is the number of cutting intervals, the tool wear distribution of each tool position pair is calculated, and all CR after the complete part is machined are obtained by superpositionsCorresponding wear amount W ═ Ws1., S }; if the first point in the current point pair is the last point of one tool path and the second point is the starting point of the next tool path, the tool abrasion loss is not calculated under the condition;
step four, cutter shaft optimization;
for tool track TpuAnd (U is 1, U), wherein U is the number of tool paths, the intersection of all tool position point interference-free tool shaft spaces of the tool paths is solved to obtain a common interference-free tool shaft space, a tool shaft is optimized based on a genetic algorithm, the cutting length, the abrasion loss and the abrasion loss variance of S cutting intervals under the tool path combination are calculated according to the third step, and finally the optimal tool shaft combination is output.
2. The arbor optimization method of claim 1, wherein: if the first point in the current point pair is the starting point of one tool path, according to Pa1The processing method of (1) calculating the tool-workpiece engagement area, solving the blank removal body and updating the blank state.
3. The arbor optimization method of claim 2, wherein: pa is1The processing method comprises the following steps: constructing a ball nose tool geometry T according to the tool radius, at p1Performing Boolean intersection operation on the T and the part blank to obtain p1The surface of the tool-workpiece meshing area solid where the tool geometric body T is tangent to the meshing area solid is p1Tool-workpiece engagement area CWE of1And constructing a CWE1Point set of
E is a region CWE1The number of discrete points; at the same time, for Pa1Interpolating the cutter axis vectors of the two cutter location points, dispersing the cutter geometry T into point cloud to construct a cutter swept volume TS1And to TS1And a blankPerforming Boolean intersection operation, and deleting the intersection part from the blank to obtain the update state R of the blank1The intersecting part is defined as a blank removing body Tb1。
4. The arbor optimization method of claim 1, wherein: if the first point in the current point pair is the last point of one tool path and the second point is the starting point of the next tool path, the Boolean intersection operation is only needed to be carried out on the T at the first point and the previous blank removing body, the tangent surface of the T and the blank removing body is calculated, the calculated surface is the tool-workpiece meshing area at the first point, at the moment, a tool swept body between the two points is not needed to be constructed, the blank updating state is the same as that of the previous point pair, the steps are repeated until all the point pairs in Pa are traversed, and the tool-workpiece meshing area CWE at all the tool positions is obtained, wherein CWE is { CWE { (CWE) } CWEt|t＝1，...，n}。
5. The arbor optimization method of claim 4, wherein: for Pa2Calculating T at p2Is and Tb1Tangential surface, obtaining a surface p2Tool-workpiece engagement area CWE of2And constructing a CWE2Point set of
Calculating TS according to the same method2Then through the current blank R1Performing Boolean operation to obtain processed Pa2Rear blank R2，TS2And R1The crossed part is a blank removing body Tb2(ii) a Repeating pairs Pa for subsequent pairs of tool sites2The blank removing body is solved, the tool-workpiece meshing area is calculated, the blank is updated, the steps are repeated until all the point pairs in Pa are traversed, and the tool-workpiece meshing areas CWE (CWE) at all the tool positions are obtainedt|t＝1，...，n}。
6. The arbor optimization method of claim 2 or 4, wherein: in the second step, the knife position point is pointedptEstablishing a Gaussian sphere by taking the point as the center of the sphere, and dispersing the Gaussian sphere into a point set S ═ Sg＝(xg，yg，zg) 1.. G }, where G is the number of discrete points, then p istsgInitial arbor space of this point, ptsgA point b (x (m), y (m), z (m)) between, m > 0, satisfying:
according to the updated blank Rt-1And constructing point cloud model to obtain point set
O is
Number of points and satisfies rpob⊥ptsgObtaining rpoThe distance to point b is shown as
7. The arbor optimization method of claim 1, wherein: in the third step, the distance range [ l ] from each section to the cutter shaft is calculatedmin，lmax](ii) a Set point pair PatAccording to the CWE obtained in the step onetPoint set
The distance from the cutter shaft to the cutter shaft judges which cutting intervals participate in cutting; wherein the arc length corresponding to the two points at the farthest interval in the s-th interval is set as the cutting length l of the interval; at PatThe wear distance of the section s is obtained by the length d of the tool path between the tool contacts corresponding to the two points, wherein d can be approximate to the linear distance between the two tool contacts and the section CR3Is calculated by equation (2):
wherein d and l represent the machining point pair PatCorresponding tool path length and cutting length of section s, FzZ is the number of cutting edges for each tooth feed.
For the cutting edge portion of the ball nose tool, the cutting speed of the section s can be expressed by the formula (3):
wherein r' represents the average distance from the cutting section to the cutter shaft, and N is the main shaft rotating speed.
Calculating the wear rate of the cutter interval s by adopting a formula (4):
VB＝KVg aFz b(4)
wherein K is a service life coefficient, and a and b are coefficients of influence of cutting speed and feed quantity on the service life degree of the cutter;
then, according to the formulas (2) and (4), determining the abrasion loss w of the section s after the whole curved surface is processed, as shown in the formula (5): w ═ VBL (5)。
Wherein, L here is the wear distance of the section s after the whole curved surface is processed.
8. The arbor optimization method of claim 1, wherein: in the fourth step, the abrasion loss of S cutting intervals under the tool path combination is calculated according to the third step, reasonable initial parameters are set based on a genetic algorithm, after one-time selection, crossing and variation operation is carried out, the abrasion loss value of each interval is recalculated, and the abrasion loss variance delta is calculated2The calculation is as shown in equation (6)
Wherein s is the number of cutting intervals,
the average value of the wear amounts of the S sections is shown.
9. The arbor optimization method of claim 8, wherein: and setting the cutter shaft direction for fixing each cutter rail as an angle theta, wherein the value of the angle theta is selected from the public non-interference cutter shaft space of each cutter rail and corresponds to different cutter shaft vectors.
10. The arbor optimization method of claim 9, wherein: corresponding to the cutter shaft vectors of different theta angles, according to the obtained CWE, recalculating the cutting length and the abrasion loss of each interval according to the step three, and then calculating the abrasion loss variance delta under the new combination2And when the iteration times are reached, selecting the cutter shaft vector corresponding to the minimum variance combination as an optimal cutter shaft processing mode for processing the part.
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