CN113377069B - Mixed milling cutter path generation method for machining blisk blade profile - Google Patents
Mixed milling cutter path generation method for machining blisk blade profile Download PDFInfo
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- G05B19/00—Programme-control systems
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- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/4097—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by using design data to control NC machines, e.g. CAD/CAM
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Abstract
The invention discloses a method for generating a mixed milling cutter path for machining a blisk blade profile, which comprises the steps of constructing an equidistant curved surface on a blade curved surface, constructing a layered surface in the direction from a blade tip to a blade root, and calculating the intersection line of the equidistant curved surface and the layered surface to obtain a trajectory line of a mixed milling cutter path of rough machining, semi-finish machining and finish machining; sequencing the trajectory lines according to a ladder-shaped sequencing method to obtain a rough machining-semi-finish machining cutter path mixed milling cutter path; the lateral inclination angle range of the cutter shaft vector of the milling cutter is obtained by controlling the contact range of the cutting edge of the ball head cutter during milling; and respectively generating cutter shaft vector ranges of rough machining, semi-finish machining and finish machining cutter paths through the lateral inclination angle range, and milling the cutter in the cutter shaft vector range on the mixed milling cutter path. According to the invention, the mixed milling cutter path is generated and the same cutter is used for milling on the mixed milling cutter path, so that no cutter is changed and cutter marks are avoided; the quality of the milling surface is ensured by controlling the contact range of the cutting edge of the ball head cutter, and the service life of the cutter is prolonged.
Description
Technical Field
The invention relates to the technical field of numerical control milling machining and manufacturing, in particular to a method for generating a hybrid milling cutter path for machining a blisk blade profile.
Background
The blisk parts are core components of aerospace engines, and the quality of blisk parts has important influence on the pneumatic performance and the working reliability of the engines. Machining modes of the parts comprise casting, 3D printing, electric spark, numerical control milling and the like, wherein the numerical control milling is commonly used for fine machining of blisk blade profiles.
The types of the blisk blades in the blisk blade type parts are different, but the blisk blades need to be integrally machined during machining, so that the machining precision requirement is high. And the traditional fine machining blade with longer overhang has low rigidity, and is easy to deform, vibrate, give way and the like during machining, so that the surface of a finally formed part has larger errors, and the quality is reduced. Currently, there is a method of increasing the machining rigidity by filling the space between the blades with a material, but this method adds an additional process step. The tool paths are divided into rough machining, semi-finishing machining and finishing machining to improve the precision, but the different machining tool paths lack natural consistency and easily generate tool catching marks on the surfaces of parts. Therefore, there is a method of using Computer Aided Manufacturing (CAM) to perform tool path blending, which generates tool location files for rough machining, semi-finishing and finishing, then generates a blended tool path including tool paths for rough machining, semi-finishing and finishing through parsing a plurality of tool location files, uniform layering again, and combining processes, and finally estimates the total tool lowering depth by calculating the average Z value of the rough machining trajectory; the method guarantees that no interference occurs between rough machining, semi-finishing and finishing tool paths based on the estimated Z value, but because different tools are adopted for rough machining and finishing machining, tool catching marks are still generated due to tool changing actions during conversion of rough machining and finishing machining [2]. In addition, the existing hybrid milling cutter path adopts simple layer-by-layer milling, each milling layer comprises rough machining, semi-finish machining and finish machining cutter paths, when the rough machining milling amount is larger than the radius of the cutter, the part of a cutter point close to the ball head cutter can participate in milling, the milling working condition is poor, the cutter is easy to damage, the machining surface quality is reduced, and the service life of the cutter is shortened [1].
Reference:
[1] yuan Meng Song, xuwei bin, wu Chong Shen, yangming, shjin Yu. CN106216748A,2016-12-14.
[2] The method for generating the rough machining-semi-finishing tool path milling mixed path of the integral impeller comprises the following steps: CN103645674B,2013-11-29.
Disclosure of Invention
Therefore, the technical problem to be solved by the invention is to overcome the defects in the prior art, and provide a method for generating a hybrid milling cutter path for rough machining, semi-finish machining and finish machining, which can generate a reasonable arrangement sequence of the hybrid milling cutter path for rough machining, semi-finish machining and finish machining, and can enable the cutter path to use the cutter cutting edges according to types and regions, prevent the cutter point part of a ball head cutter from participating in milling, protect the finish machining cutting edges, further prolong the service life of the cutter and ensure the finish machining milling quality.
In order to solve the technical problem, the invention provides a method for generating a hybrid milling cutter path for machining a blisk blade profile, which comprises the following steps:
step 1: defining one side of a blade connected with a hub as a blade root, defining the other side of the blade far away from the hub as a blade tip, constructing a plurality of corresponding equidistant curved surfaces at different offset distances respectively based on the original curved surfaces of the blade, constructing a series of layered surfaces in the direction from the blade tip to the blade root, and calculating the intersection line of the equidistant curved surfaces and the layered surfaces to obtain the trajectory line of the rough machining-semi-finish machining cutter path mixed milling cutter path;
step 2: sequencing the trajectory lines of the rough machining-semi-finish machining cutter path mixed milling cutter path according to a ladder-shaped sequencing method to obtain a rough machining-semi-finish machining cutter path mixed milling cutter path;
and step 3: the lateral inclination angle range of the cutter shaft vector of the ball head cutter path is obtained by controlling the contact range of the cutting edge of the ball head cutter during the milling of the rough machining-semi-finish machining cutter path hybrid milling cutter path, the cutter shaft vector ranges of the rough machining cutter path, the semi-finish machining cutter path and the finish machining cutter path are respectively generated through the lateral inclination angle range, and the cutter mills in the cutter shaft vector range of the rough machining-semi-finish machining cutter path hybrid milling cutter path.
Further, in step 1, a plurality of corresponding equidistant curved surfaces are respectively constructed based on the original blade curved surface at different offset distances, and the specific process is as follows:
the rough machining and the semi-finish machining in the rough machining-semi-finish machining cutter path mixed milling cutter path are defined as rough machining, the equidistant curved surface of the blade curved surface S is defined as O (x), and x represents the distance between the two curved surfaces; defining the machining allowance of the blade as c, and defining the ball head radius of a milled ball head cutter as R; definition ofFinish machining with total milling thickness d finish And the number of tool paths for completing milling is
Defining the total milling thickness of rough machining as d rough And the number of milling paths is N rough ；
Calculating the distance from the sphere center of the cutter ball head to the blade S in each cutter path to obtain an equidistant surface where the cutter sphere center is located, and N is from the inner side to the outer side rough The equidistant surface of the rough processing of the strips is as follows: n th rough Strip rough machining equidistant surface
N th rough -1 rough machined equidistant surface
1 st rough machining equidistant surface O (R + c + d) finish )；
From the inner side to the outer side of N finish The strip finish machining equidistant surface is: n th finish Equidistant surface for strip finishing
N th finish -1 bars of fine machined equidistant surfaces
Finish equidistant surface O (R + c) of No. 1.
Further, in the step 1, when a series of layered surfaces are constructed in the direction from the blade tip to the blade root, a linear interpolation mode is adopted to construct a layered surface between the curved surface where the blade tip of the blisk model is located and the hub surface, and the constructed layered surface is a plane or a curved surface.
Further, a layered surface is constructed between the curved surface where the blade tip of the blisk model is located and the hub surface by adopting a linear interpolation mode, and the specific process is as follows:
defining a depth parameter at a blade tip as 0, a depth parameter at a blade root as 1, defining L (u) as a layering plane, and defining u as a depth parameter;
defining a Ratio which represents the Ratio of the number of finished layers to the number of rough machining layers, wherein the value of the Ratio is a positive integer; defining the number of finishing layers as
In u ∈ [0, 1]]The obtained layering surface is as follows:
and generating rough machining and finish machining layered surfaces with consistent cutter routes, selecting the rough machining layered surfaces from the finish machining layered surfaces according to the layer Ratio, and obtaining the structural layered surfaces as follows:
wherein the symbol
Indicating that the fractional part of the calculation result is discarded.
Further, when the rough machined layered surfaces are selected from the finished layered surfaces in accordance with the layer number Ratio
And
and when the thicknesses are not equal, the layering surface L (1) is also used as a rough processing layering surface for ensuring that the layering surface L (1) at the blade root is shared by rough processing and finish processing cutter paths.
Further, the step 1 of calculating the intersection line of the equidistant curved surface and the layered surface to obtain the trajectory line of the rough machining-semi-finishing tool path hybrid milling tool path specifically comprises the following steps:
designing a storage mode of the cutter path, respectively and gradually solving intersection lines of the rough machining layered surface and the rough machining cutter center equidistant surface and the finish machining layered surface and the finish machining cutter center equidistant surface in a surface-surface intersection mode, storing the intersection lines in the storage mode of the cutter path and outputting the intersection lines to obtain a trajectory line of the rough machining-semi-finish machining cutter path hybrid milling cutter path.
Further, the storage mode of the tool path is as follows: each cutting layer comprises a rough machining cutter path and a finish machining cutter path at the same time or only comprises a finish machining cutter path, and each cutter path comprises a cutter path track line and a cutter path serial number.
Further, in the step 2, the trajectory lines of the rough machining-semifinishing machining-finish machining tool path mixed milling tool paths are sequenced according to a ladder-shaped sequencing method to obtain the rough machining-semifinishing machining-finish machining tool path mixed milling tool paths, and the ladder-shaped sequencing method specifically comprises the following steps:
step 2.1: initializing the total cutting layer number to be ML, wherein a tool path counting index I =0, all tool paths are in a state of not setting serial numbers, and defining a cutting layer as a rough machining and finish machining common layer as an RF layer and a cutting layer as a finish machining layer as an F layer; definition of
The J-th pass represents the L-th cutting layer, where L e [0]；
Step 2.2: firstly, the last cutting tool path is processed, and the last finish machining tool path of the last cutting layer is judged
Whether the serial number is set or not, if so, executing step 2.9; if not, executing step 2.3 to set the tool path
The serial number of (2);
step 2.3: preparation setting tool path
Number of (1), if
If not, jumping to step 2.2; if J =0, it means
If the finish machining tool path is finished, executing a step 2.4, and if J is not equal to 0, executing a step 2.5;
step 2.4: step 2.3 of setting the tool path
The last cutting layer of
Setting a serial number, and then continuing to execute the step 2.6;
step 2.5: step 2.3 of setting tool path
Last RF layer of (A)
Setting a serial number, and then continuing to execute the step 2.6;
step 2.6: step 2.3 of setting tool path
The outside cutter path of the same layer
Setting the serial number, executing step 2.3 to the outer cutter path of the next RF layer according to the sorting rule
Setting a serial number; if it is
Is the finish machining tool path of the RF layer, step 2.7 is executed to set the feeding sequenceThe outside tool path number of the previous RF layer; if it is
A finishing tool path other than the RF layer, perform step 2.8;
step 2.7: carry out step 2.3 pairs in feed order
Outer cutter path of the previous RF layer
Setting a serial number, and then continuing to execute the step 2.8;
step 2.8: setting up
The serial number is I, and the I is increased by 1; step 2.9 is executed;
step 2.9: and finishing the sequencing to obtain a rough machining-semi-finish machining tool path mixed milling tool path which is arranged according to the milling sequence.
Further, in the ladder-shaped sequencing method, in the process of sequencing the trajectory of the rough machining-semi-finish machining cutter path mixed milling cutter path, when each rough machining cutter path is milled, all rough machining cutter paths on the outer side of the rough machining cutter path corresponding to the next rough machining layer are kept to be milled, so that the cutter tip is prevented from participating in milling;
and simultaneously, when the finish machining tool path is milled, all rough machining tool paths on the current layer and all tool paths on all layers facing to the blade tip direction are ensured to be milled, and when the finish machining tool path is milled except for the last layered surface at the blade root, all rough machining tool paths on the next adjacent rough machining layer on the layer are ensured to be milled, so that the interference between the rough machining tool paths and the finish machining tool paths is avoided.
Further, in the step 3, by controlling the contact range of the ball head cutter cutting edge during the milling of the rough machining-semi-finish machining tool path hybrid milling tool path, the lateral inclination angle range of the tool axis vector of the rough machining-semi-finish machining tool path hybrid milling tool path is obtained, and the tool axis vector ranges of the rough machining tool path, the semi-finish machining tool path and the finish machining tool path are respectively generated through the lateral inclination angle range, which specifically includes:
step 3.1: defining the ball point of the cutter ball head as the origin of a local coordinate system of the cutter, and defining the upper limit of the available height of a rough cutting edge as H rough And the radius of the ball head cutter is R, the contact height range of the rough machining cutting edge is [0 rough ]The contact height range of the finish machining cutting edge is H rough ,R]；
Step 3.2: defining the side inclination angle of the cutter as alpha, wherein the alpha represents the angle of the cutter in the direction away from the blade, and the side inclination angle corresponding to the upper limit of the available height of the rough cutting edge is
Further obtains the lateral inclination angle range of the rough machining tool path cutter shaft vector as
Side dip range of finish machining tool path cutter axis vector
Step 3.3: the tangents of the cutting contact point on the blade corresponding to the cutting contact point on the cutter cutting edge along the U and V directions of the blade are defined as tau respectively u ,τ v At τ u Is the vector initial direction of the cutter shaft, and is over-cut contact point P and parallel to tau v The straight line in the direction is taken as a rotation axis, and the rotation direction far away from the blade is taken as a positive direction, and corresponding rotation transformation is defined to be M α And obtaining the range of the rough machining cutter shaft vector L as follows:
the range of the finish machining cutter shaft vector L' is as follows:
compared with the prior art, the technical scheme of the invention has the following advantages:
(1) The path lines of the rough machining-semi-finish machining tool path mixed milling tool paths are generated by constructing equidistant curved surfaces and layered surfaces, and then the reasonable rough machining-semi-finish machining tool path mixed milling tool paths are obtained by arranging the path lines through a ladder-shaped sorting method, so that the process is simple; the same cutter is used for milling on the mixed milling cutter path, so that cutter changing is not performed, the problem of cutter receiving marks caused by the cutter changing process in the milling process is avoided, the cutter changing time is saved, and the efficiency is improved.
(2) Cutter shaft vectors of rough machining, semi-finish machining and finish machining cutter paths are generated through a lateral inclination angle, different parts of the ball head are respectively adopted for milling, the influence on finish machining milling caused by abrasion of the rough machining milling cutter is reduced, and the quality of a milling surface is ensured; meanwhile, under the condition that the total milling cutter path length is not increased, the situation that the part close to the cutter point of the cutter participates in milling is effectively avoided, the abrasion to the cutter is reduced, and the service life of the cutter is prolonged.
Drawings
In order that the present disclosure may be more readily and clearly understood, reference will now be made in detail to the present disclosure, examples of which are illustrated in the accompanying drawings.
FIG. 1 is a flow chart of the present invention.
Fig. 2 is a schematic view of a model of a blade according to the invention.
Fig. 3 is a schematic diagram of a milling process of two adjacent rough machining tool paths when the conventional hybrid milling tool paths are simply sequenced.
Fig. 4 is a schematic diagram of a milling sequence in accordance with the present invention.
FIG. 5 is a schematic representation of the results of the present invention using a ladder sorting method on a cross-section of the blade model of FIG. 2.
FIG. 6 is a flow chart of a ladder sorting method of the present invention.
Fig. 7 is a schematic diagram of the present invention showing the use of ball nose tool cutting edges in different areas.
Fig. 8 is a schematic view of the range of the arbor vector in the present invention.
FIG. 9 is a schematic diagram of a combined roughing-semi-finishing tool path milling tool path obtained in an embodiment of the present invention.
Detailed Description
The present invention is further described below in conjunction with the following figures and specific examples so that those skilled in the art may better understand the present invention and practice it, but the examples are not intended to limit the present invention.
In the description of the present invention, it should be understood that the term "comprises/comprising" is intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a list of steps or elements is not limited to the listed steps or elements but may alternatively include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus.
Referring to fig. 1, a flowchart shows an embodiment of a method for generating a hybrid milling cutter path for machining a blisk blade profile according to the present invention, which includes:
step 1: defining one side of the blade connected with the hub as a blade root, and defining the other side of the blade far away from the hub as a blade tip; constructing a plurality of corresponding equidistant curved surfaces based on the original blade curved surfaces at different offset distances, wherein the layered surfaces are planes or curved surfaces; and constructing a series of layered surfaces in the direction from the blade tip to the blade root, and calculating the intersection line of the equidistant curved surface and the layered surfaces to obtain the trajectory of the rough machining-semi-finish machining cutter path mixed milling cutter path.
Step 1.1: a series of equidistant curves of different distances are constructed on the blade curve.
Step 1.1.1: as shown in the model diagram of the blade in fig. 2, rough machining and semi-finish machining in the rough machining-semi-finish machining tool path mixed milling tool path are defined as rough machining, an equidistant curved surface of a curved surface S of the blade is defined as O (x), and x represents the distance between the two curved surfaces; defining the machining allowance of the blade as c, and defining the ball head radius of a milled ball head cutter as R; defining the total milling thickness of finishing as d finish And the number of tool paths for completing milling is
Thickness d finish Materials of
Secondary milling is performed, in fact
Take the constant value 1. Defining the total milling thickness of rough machining as d rough And the number of milling paths is N rough (ii) a Thickness d rough Is divided into N rough And finishing milling.
Step 1.1.2: calculating the distance from the center of the cutter ball head to the blade S in each cutter path to obtain an equidistant surface where the cutter ball head is located, and gradually increasing the distance from the inner side to the outer side to obtain N rough Strip rough machining equidistance face is ordered, and the order is:
n th rough Strip rough machining equidistant surface
N th rough -1 rough machined equidistant surface
…，
No. 1 rough machining equidistant surface O (R + c + d) finish )；
N from inner side to outer side according to distance from small to large finish The strip finish machining equidistant surfaces are sequenced in the sequence:
n th finish Equidistant surface for strip finishing
N th finish -1 fine machined equidistant surface
…，
Finish equidistant surface O (R + c) of No. 1.
Step 1.2: a layered surface is constructed between the curved surface where the blade tip of the blisk model is located and the hub surface in a linear interpolation mode, and the constructed layered surface is a plane or a curved surface.
Step 1.2.1: defining a depth parameter at a blade tip as 0, a depth parameter at a blade root as 1, defining L (u) as a layering plane, and u represents the depth parameter;
step 1.2.2: the key point of rough machining is that a large amount of materials are removed quickly, the number of layers of a rough machining cutter path is not more than that of layers of finish machining, in order to realize consistent layering, ratio is defined to represent the Ratio of the number of layers of finish machining to the number of layers of rough machining, and the value of Ratio is a positive integer; defining the number of finishing layers as
In u ∈ [0, 1]]The obtained layering surface is as follows:
and generating rough machining and finish machining layered surfaces with consistent cutter routes, and selecting the rough machining layered surfaces from the finish machining layered surfaces according to the layer Ratio as follows:
wherein the symbols
Representing the fraction part in the rejection calculation result; when in use
And with
When the thicknesses are not equal, the layered surface L (1) is particularly used as a rough layered surface, so that the layered surface L (1) at the blade root is ensured to be shared by rough machining and finish machining tool paths.
Step 1.3: and calculating the intersection line of the equidistant curved surface and the layered surface to obtain the trajectory line of the rough machining-semi-finish machining tool path mixed milling tool path.
The storage mode of designing the cutter path is as follows: each cutting layer can simultaneously comprise a rough machining tool path and a finish machining tool path, or only comprise a finish machining tool path, each tool path comprises a tool path trajectory Line and a tool path serial number Index, and the tool path serial number Index is used for tool path sequencing.
Based on a designed tool path storage mode, intersecting lines of a rough machining layered surface and a rough machining tool center equidistant surface and a finish machining layered surface and a finish machining tool center equidistant surface are respectively and successively solved in a surface-surface intersection mode, and the intersecting lines are tool path lines to obtain the path lines of the rough machining-semi-finish machining tool path mixed milling tool paths.
And 2, step: and sequencing the trajectory of the rough machining-semi-finish machining tool path hybrid milling tool path according to a ladder-shaped sequencing method to obtain the rough machining-semi-finish machining tool path hybrid milling tool path, thereby achieving the effect of preventing the tool tip part of the ball head tool from participating in cutting.
Fig. 3 is a schematic diagram of milling processes of two adjacent rough machining tool paths in simple sequencing of the conventional hybrid milling tool path, wherein in simple sequencing, when the rough machining milling amount is large, the part close to the tool nose of the two adjacent rough machining tool paths on the same layer participates in milling, d in the diagram represents the total rough machining cutting thickness, and it can be seen from the part encircled by the oval dotted line in the diagram that when the total rough machining milling thickness d is large relative to the radius of the tool, the part close to the tool nose of the ball head tool participates in milling.
As shown in fig. 4, which is a schematic diagram of the milling sequence of the present invention, the outermost tool path is a rough tool path having the largest distance from the blade in the cutting layer, and the next outermost tool path is a rough tool path adjacent to the outermost tool path. In the drawing, 41 denotes an outermost tool path for milling a current rough machining layer, 42 denotes an outermost tool path for milling a next rough machining layer, 43 denotes a tool path for retreating from the next rough machining layer to the current rough machining layer, and 44 denotes a next outermost tool path for milling the current rough machining layer.
FIG. 5 is a cross-sectional view of the hybrid milling cutter path of the blade model of FIG. 2, with the horizontal dashed line on the right side of the figure indicating a cutting layer and the symbol RF on the left side indicating that the cutting layer is roughA common layer for machining and finishing, wherein F represents that the cutting layer is a finishing layer; the longitudinal dotted line represents a cross-sectional view of the equidistant surface of the blade; the intersection point of the horizontal dotted line and the vertical dotted line represents a cutting tool path; the numbers represent the milling sequence of the tool paths, wherein the bold numbers represent rough machining tool paths, corresponding to black dots, and the non-bold numbers represent finish machining tool paths, corresponding to gray dots. Not all tool paths are shown in the figure, and the core idea of the invention can be highlighted by the shown parts, namely the tool paths with the serial numbers of 1-13. Drawing and setting parameters Ratio =2 and the number of finishing tool paths according to the definition of the step 1
Number of rough machining passes N rough And =3 for rendering.
The key point of the ladder-shaped sequencing method is that when each rough machining tool path is milled, all rough machining tool paths on the outer side (the side with larger blade equidistant surface distance) of the rough machining tool path corresponding to the next rough machining layer are kept to be milled, namely, materials close to a tool nose part in rough machining are removed, and the problem that the tool nose participates in milling is avoided as much as possible. Meanwhile, in order to avoid the interference between the rough machining tool path and the finish machining tool path, the finish machining tool path is milled by ensuring that all rough machining tool paths on the layer and all tool paths on all layers facing to the blade tip direction are milled; in order to further avoid interference, besides the last layered surface at the root of the blade, the finish machining tool path is milled while ensuring that all rough machining tool paths on the next adjacent rough machining layer of the layer are milled. For example, when the outermost roughing tool path of the first roughing layer is to be milled after the milling is completed and the next outermost roughing tool path of that layer is to be milled, it is ensured that the outermost roughing tool path of the second roughing layer has been milled. When milling the finishing tool path of layer 3, it should be ensured that all the roughing tool paths on layer 4 (next adjacent roughing layer, second roughing layer) have completed milling. For example, in fig. 5, before the fine tool path with the number 10 starts to cut, it is necessary to ensure that the tool paths 9, 5, and 2 in the next rough layer have finished cutting, and it is not necessary to ensure that all the rough tool paths in the cutting layers with the numbers 8 and 4 have finished cutting. When the number of rough machining layers needing to be milled when the finish machining tool paths begin to mill is 2, all rough machining tool paths in the layers where the No. 8 and No. 4 tool paths are located need to be further ensured to be cut completely.
Based on the above analysis, the various knife paths obtained are sorted by using a ladder sorting method, and the sorting process of the ladder sorting method is shown in the flowchart of fig. 6. Wherein:
sort (L, J) is a sorting algorithm handler, and the Sort (L, J) is called recursively in the algorithm;
l is the cutting layer being sequenced;
j is the serial number of the tool path being processed, the rough-fine tool paths are numbered uniformly and arranged from inside to outside, the fine machining tool path on the blade side in the same layer is J =0, the first rough machining tool path is J =1, note that the number of the fine machining tool paths is N finish ＝1；
PrevRL is the last RF layer of L layer, blade tip side;
PrevFeedRL is the preceding cutting RF layer of the L layers in feed order;
NextRL is the next RF layer of the L layers;
for convenience, all index numbers are counted from 0; there are a large number of recursive calls to this algorithm.
Step 2.1: initializing the total cutting layer number to be ML, wherein a tool path counting index I =0, all tool paths are in a state of not setting serial numbers, and the cutting layer is a rough machining and finish machining common layer and is defined as an RF layer, and the cutting layer is a finish machining layer and is defined as an F layer; definition of
The jth tool path representing the lth cutting layer, where L e [0]；
Step 2.2: firstly, the last cutting tool path is processed, and the last finish machining tool path of the last cutting layer is judged
Whether the serial number is set or not, if so, executing step 2.9; if not, executing step 2.3 to set the tool path
The serial number of (2);
step 2.3: tool path preparation setting
Number of (1), if
If not, jumping to step 2.2; if J =0, it means
If the finish machining tool path is finished, executing a step 2.4, and if J is not equal to 0, executing a step 2.5;
step 2.4: step 2.3 of setting the tool path
The last cutting layer of
Setting a serial number, and then continuing to execute the step 2.6;
step 2.5: step 2.3 of setting the tool path
The last RF layer of
Setting a serial number, and then continuing to execute the step 2.6;
step 2.6: step 2.3 of setting the tool path
The outside cutter path of the same layer
Setting the serial number, executing step 2.3 to the outer cutter path of the next RF layer according to the sorting criterion
Setting a serial number; if it is
If the layer is the finish machining cutter path of the RF layer, executing step 2.7 to set the serial number of the outer cutter path of the previous RF layer according to the feeding sequence; if it is
A finishing tool path other than the RF layer, step 2.8 is performed;
step 2.7: carry out step 2.3 pairs in feed order
Outer cutter path of the previous RF layer
Setting a serial number; then continuing to execute step 2.8;
step 2.8: setting up
The serial number is I, and the I is increased by 1; step 2.9 is executed;
step 2.9: and finishing the sequencing to obtain a rough machining-semi-finish machining tool path mixed milling tool path which is arranged according to the milling sequence.
And 3, step 3: the lateral inclination angle range of the cutter shaft vector of the rough machining-semi-finish machining cutter path is obtained by controlling the contact range of the cutting edge of the ball head cutter during the milling of the rough machining-semi-finish machining cutter path mixed cutter path, the cutter shaft vector ranges of the rough machining, semi-finish machining and finish machining cutter paths are respectively generated through the lateral inclination angle range, and the cutter mills in the cutter shaft vector range on the rough machining-semi-finish machining cutter path mixed cutter path. The different types of tool paths use different cutting edge regions of the tool, the fine machining cutting edge region is protected, the abrasion of the region is reduced, the service life of the tool is prolonged, and the quality of the fine machining surface is guaranteed.
Step 3.1: because the hybrid milling cutter path comprises an additional rough-semi-fine milling cutter path, a longer milling path is needed for finishing the blade profile, the abrasion of the rough milling cutter to the cutter is more serious than that of the fine milling cutter, and the practical application object of the hybrid milling cutter path is usually a blade with longer overhang, so that the service life of the cutter is greatly tested. Thus, the present invention employs a manner of zone division of the ball nose tool cutting edge, assigning different cutting edge zones to the rough-semi-finish path and the finish path, respectively, as shown in fig. 7. Defining the ball point of the ball head of the cutter as the origin of a local coordinate system of the cutter, and defining the upper limit of the available height of a rough cutting edge as H rough And the radius of the ball head of the cutter is R, the contact height range of the rough cutting edge is [0 rough ]The contact height range of the finish machining cutting edge is [ H ] rough ,R]Therefore, the contact points on the cutting edges of the tool corresponding to different tool paths must fall within the corresponding ranges.
Step 3.2: defining the lateral inclination angle of the cutter as alpha, representing the angle of the cutter in the direction away from the blade, and corresponding to the lateral inclination angle at the upper limit of the available height of the rough cutting edge
Further obtains the lateral inclination angle range of the rough machining tool path cutter shaft vector as
Side dip range of finishing tool path cutter shaft vector
Step 3.3: solving the cutter axis vector L under the constraint of the range, and defining the tangents of the cutting contact points on the blade corresponding to the cutting contact points on the cutting edge of the cutter along the U and V directions of the blade as tau respectively u ,τ v UV direction, shown in FIG. 2, at τ u Is the vector initial direction of the cutter shaft, and is over-cut contact point P and parallel to tau v The straight line of the direction is used as a rotating shaftA line defining a corresponding rotation transformation M with the direction of rotation away from the blades as the positive direction α And obtaining the range of the rough machining cutter shaft vector L as follows:
the range of the finish machining cutter shaft vector L' is as follows:
as shown in fig. 8, in order to ensure the cutting edge range limited by the milling tool path, the contact points on the ball nose tool are limited to fall in the designated area. The cutter shaft vector range is generated by adjusting the lateral inclination angle, so that the position of a contact point on a cutter can be changed under the condition that the position of a cutter center of a ball head cutter and the contact point on a blade milling model (a model shown in figure 2) are not changed, the contact point on the ball head cutter falls into a formulated area, and the formulated area is the cutting edge area.
To further illustrate the beneficial effects of the present invention, the present invention is applied to a blade finishing strategy of CAM software in this embodiment, and the hybrid milling path form described in the present invention is obtained by the following steps:
step a: initializing the model and creating a blade finishing strategy, setting the necessary parameters: the diameter of the ball head cutter is 10mm, the taper is 3mm, the edge part length is 20mm, the cutter length is 80mm, the rotating speed of a machine tool main shaft is 3000r/min, and the feeding amount is 1000mm/min.
Step b: starting a hybrid milling mode (step finishing in CAM software), setting machining parameters: fine machining distance of 0.25mm, rough machining distance of 2mm, rough machining tool path number of 3, fine-rough layer number ratio example 3, pre-rough machining layer number of 3 and rough machining distribution layer number of 1.
Wherein, the distance of the fine machining and the distance of the rough machining respectively correspond to the total milling thickness of the fine machining and the rough machining of the invention, and the default number of the fine machining cutter paths in software is 1; the number of layers to be rough machined is the number of RF layers completely milled under the layer during milling of the F layer, and the essence of the invention can be highlighted in consideration of the value of 1 (as shown in fig. 5, the number of layers to be rough machined (the number of layers to be rough machined) in the rough machining layer under the current layer before the finish machining tool path starts to cut is the number of layers to be rough machined in which all rough machining tool paths have been cut in the rough machining layer under the current layer, so the invention emphasizes avoiding cutting at the ball tip part, and the purpose can be achieved by taking 1 as the number of layers to be rough machined), thus parameters in realizing details are omitted; the number of rough machining step layers can be set to be 0 or 1,1 represents that the step-shaped sequencing mixed milling cutter path is started, and 0 represents that the step-shaped sequencing mixed milling cutter path is not started.
Step c: after all rough machining, semi-finish machining and finish machining tool paths are obtained by the method, the tool paths are sorted by a ladder-shaped sorting method, and the tool paths are output according to the sorting result, so that the rough machining-semi-finish machining tool path mixed milling tool path shown in the figure 9 can be obtained.
Based on the method, trial cut experiments are carried out on a certain blisk, and the profile tolerance error of the blade profile surface is required to be [ -0.05,0.05]. According to the invention, by generating the rough machining-semi-finish machining tool path mixed milling tool path and milling the ball head tool in the cutting edge area, tool changing in the machining process is avoided, the rigidity in blade machining can be improved, the machining error caused by tool back-off deformation is avoided, and tool receiving marks are avoided. The profile tolerance of the processed product is qualified, meanwhile, the abrasion of the cutter is reduced, and the service life of the cutter is prolonged. Experiments prove that the method is a key technology for forming the integral blade disc blade of the aeroengine, can effectively improve the processing precision and the surface smoothness of the blade profile, reduces the abrasion of a cutter, prolongs the service life of the cutter, reduces the use cost of the cutter, and realizes quality improvement and efficiency improvement.
Compared with the prior art, the technical scheme of the invention has the following advantages: (1) The path lines of the rough machining-semi-finish machining tool path mixed milling tool paths are generated by constructing equidistant curved surfaces and layered surfaces, and then the reasonable rough machining-semi-finish machining tool path mixed milling tool paths are obtained by arranging the path lines through a ladder-shaped sorting method, so that the process is simple; the same cutter is used for milling on the mixed milling cutter path, the cutter is not changed, the problem of cutter connecting marks caused by the cutter changing process in the milling process is avoided, the cutter changing time is saved, and the efficiency is improved. (2) Cutter shaft vectors of rough machining, semi-finish machining and finish machining cutter paths are generated through a lateral inclination angle, different parts of the ball head are respectively adopted for milling, the influence on finish machining milling caused by abrasion of the rough machining milling cutter is reduced, and the quality of a milling surface is ensured; meanwhile, under the condition that the total milling cutter path length is not increased, the part close to the cutter point of the cutter is effectively prevented from participating in milling, the abrasion to the cutter is reduced, and the service life of the cutter is prolonged.
As will be appreciated by one skilled in the art, embodiments of the present application may be provided as a method, system, or computer program product. Accordingly, the present application may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects. Furthermore, the present application may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, and the like) having computer-usable program code embodied therein.
The present application is described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the application. It will be understood that each flow and/or block of the flowchart illustrations and/or block diagrams, and combinations of flows and/or blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
It should be understood that the above examples are only for clarity of illustration and are not intended to limit the embodiments. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. This need not be, nor should it be exhaustive of all embodiments. And obvious variations or modifications of the invention may be made without departing from the scope of the invention.
Claims (10)
1. A method for generating a mixed milling cutter path for machining a blisk blade profile is characterized by comprising the following steps:
step 1: defining one side of a blade connected with a hub as a blade root, defining the other side of the blade far away from the hub as a blade tip, constructing a plurality of corresponding equidistant curved surfaces at different offset distances respectively based on the original curved surfaces of the blade, constructing a series of layered surfaces in the direction from the blade tip to the blade root, and calculating the intersection line of the equidistant curved surfaces and the layered surfaces to obtain the trajectory line of the rough machining-semi-finish machining cutter path mixed milling cutter path;
and 2, step: sequencing the trajectory of the rough machining-semifinishing-finish machining cutter path mixed milling cutter path according to a ladder-shaped sequencing method to obtain a rough machining-semifinishing-finish machining cutter path mixed milling cutter path;
and step 3: the lateral inclination angle range of the cutter shaft vector of the rough machining-semi-finish machining cutter path is obtained by controlling the contact range of the cutting edge of the ball head cutter during the milling of the rough machining-semi-finish machining cutter path mixed cutter path, the cutter shaft vector ranges of the rough machining, semi-finish machining and finish machining cutter paths are respectively generated through the lateral inclination angle range, and the cutter mills in the cutter shaft vector range on the rough machining-semi-finish machining cutter path mixed cutter path.
2. The method for generating a hybrid milling cutter path for machining a blisk blade profile according to claim 1, wherein: in the step 1, a plurality of corresponding equidistant curved surfaces are respectively constructed based on the original blade curved surface at different offset distances, and the specific process is as follows:
the rough machining and the semi-finish machining in the rough machining-semi-finish machining tool path mixed milling tool path are defined as rough machining, an equidistant curved surface of a blade curved surface S is defined as O (x), and x represents the distance between the two curved surfaces; defining the machining allowance of the blade as c, and defining the ball head radius of a milled ball head cutter as R; defining the total milling thickness of finishing as d finish And the number of tool paths for completing milling is
Defining the total milling thickness of rough machining as d rough And the number of milling-finished cutting paths is N rough ；
Calculating the distance from the sphere center of the cutter ball head to the blade S in each cutter path to obtain an equidistant surface where the cutter sphere center is located, and N is from the inner side to the outer side rough The equidistant surface of the rough processing of the strips is as follows: n th rough Strip rough machining equidistant surface
N th rough -1 rough machined equidistant surfaces
8230st, the 1 st rough machining equidistant surface O (R + c + d) finish )；
From the inner side to the outer side N finish The equidistant surface of bar finish machining is: n th finish Equidistant surface for strip finishing
N th finish -1 bars of fine machined equidistant surfaces
8230the 1 st fine machining equidistant surface O (R + c).
3. The method of generating a hybrid milling cutter path for blisk profile machining according to claim 2, wherein: in the step 1, when a series of layered surfaces are constructed in the direction from the blade tip to the blade root, a linear interpolation mode is adopted to construct a layered surface between the curved surface where the blade tip of the blisk model is located and the hub surface, and the constructed layered surface is a plane or a curved surface.
4. The method of generating a hybrid milling cutter path for machining a blisk blade profile according to claim 3, wherein: the method adopts a linear interpolation mode to construct a layered surface between a curved surface where the blade tip of the blisk model is located and a hub surface, and the specific process is as follows:
defining a depth parameter at a blade tip as 0, a depth parameter at a blade root as 1, defining L (u) as a layering plane, and defining u as a depth parameter;
defining a Ratio which represents the Ratio of the number of finished layers to the number of rough machining layers, wherein the value of the Ratio is a positive integer; defining the number of finishing layers as
In u ∈ [0, 1]]The obtained layering surface is as follows:
and generating rough machining and finish machining cutter routes consistent with each other, selecting rough machining layered surfaces from the finish machining layered surfaces according to the layer Ratio, and obtaining the structural layered surfaces as follows:
wherein the symbols
Indicating that the fractional part of the calculation result is discarded.
5. The method of generating a hybrid milling cutter path for blisk profile machining according to claim 4, wherein: when the rough machining layered surfaces are selected according to the layer Ratio from the finish machining layered surfaces
And
and when the thicknesses are not equal, the layering surface L (1) is also used as a rough processing layering surface for ensuring that the layering surface L (1) at the blade root is shared by rough processing and finish processing cutter paths.
6. The method of generating a hybrid milling cutter path for blisk profile machining according to claim 5, wherein: calculating the intersection line of the equidistant curved surface and the layered surface in the step 1 to obtain the trajectory line of the rough machining-semi-finishing machining cutter path mixed milling cutter path, which specifically comprises the following steps:
designing a storage mode of the cutter path, respectively and gradually solving intersection lines of the rough machining layered surface and the rough machining cutter center equidistant surface and the finish machining layered surface and the finish machining cutter center equidistant surface in a surface-surface intersection mode, storing the intersection lines in the storage mode of the cutter path and outputting the intersection lines to obtain a trajectory line of the rough machining-semi-finish machining cutter path hybrid milling cutter path.
7. The method of generating a hybrid milling cutter path for blisk profile machining according to claim 6, wherein: the storage mode of the knife path is as follows: each cutting layer simultaneously comprises a rough machining tool path and a finish machining tool path, or only comprises a finish machining tool path, and each tool path comprises a tool path track line and a tool path serial number.
8. The method of generating a hybrid milling cutter path for blisk profile machining according to claim 7, wherein: in the step 2, the trajectory lines of the rough machining-semi-finish machining tool path mixed milling tool path are sequenced according to a ladder sequencing method to obtain a rough machining-semi-finish machining tool path mixed milling tool path, and the ladder sequencing method comprises the following specific processes:
step 2.1: initializing the total cutting layer number to be ML, wherein a tool path counting index I =0, all tool paths are in a state of not setting serial numbers, and defining a cutting layer as a rough machining and finish machining common layer as an RF layer and a cutting layer as a finish machining layer as an F layer; definition of
The J-th pass represents the L-th cutting layer, where L e [0]；
Step 2.2: firstly, the last cutting tool path is processed, and the last finish machining tool path of the last cutting layer is judged
Whether the serial number is set or not, if so, executing step 2.9; if not, execute step 2.3 to set the tool path
The serial number of (2);
step 2.3: tool path preparation setting
Number of (1), if
If not, jumping to step 2.2; if J =0, it means
If the finish machining tool path is finished, executing a step 2.4, and if J is not equal to 0, executing a step 2.5;
step 2.4: step 2.3 of setting the tool path
The last cutting layer of
Setting a serial number, and then continuing to execute the step 2.6;
step 2.5: step 2.3 of setting the tool path
Last RF layer of (A)
Setting a serial number, and then continuing to execute the step 2.6;
step 2.6: step 2.3 of setting the tool path
Outside tool path of the same layer
Setting the serial number, executing step 2.3 to the outer cutter path of the next RF layer according to the sorting rule
Setting a serial number; if it is
If the layer is the finish machining cutter path of the RF layer, executing step 2.7 to set the serial number of the outer cutter path of the previous RF layer according to the feeding sequence; if it is
A finishing tool path other than the RF layer, perform step 2.8;
step 2.7: carry out step 2.3 pairs in feed order
Outer cutter path of the previous RF layer
Setting a serial number, and then continuing to execute the step 2.8;
step 2.8: setting up
The serial number is I, and the I is increased by 1; step 2.9 is executed;
step 2.9: and finishing the sequencing to obtain a rough machining-semi-finish machining tool path mixed milling tool path which is arranged according to the milling sequence.
9. The method of generating a hybrid milling cutter path for blisk profile machining according to claim 8, wherein: in the step-shaped sequencing method, in the process of sequencing the trajectory lines of the rough machining-semi-finish machining tool path mixed milling tool paths, when each rough machining tool path is milled, all rough machining tool paths on the outer side of the rough machining tool path corresponding to the next rough machining layer are kept to be milled, so that a tool nose is prevented from participating in milling;
and simultaneously, when the finish machining tool path is milled, all rough machining tool paths on the current layer and all tool paths on all layers facing to the blade tip direction are ensured to be milled, and when the finish machining tool path is milled except for the last layered surface at the blade root, all rough machining tool paths on the next adjacent rough machining layer of the current layer are ensured to be milled, so that interference between the rough machining tool paths and the finish machining tool paths is avoided.
10. The method of generating a hybrid milling cutter path for blisk profile machining according to claim 9, wherein: in the step 3, a lateral inclination angle range of a cutter shaft vector of the ball head cutter during milling of the rough machining-semi-finish machining cutter path is obtained by controlling a contact range of a cutting edge of the ball head cutter during milling of the rough machining-semi-finish machining cutter path, and cutter shaft vector ranges of the rough machining cutter path, the semi-finish machining cutter path and the finish machining cutter path are respectively generated through the lateral inclination angle range, and the method specifically comprises the following steps:
step 3.1: defining the ball point of the cutter ball head as the origin of the local coordinate system of the cutter, and defining the upper limit of the available height of the rough cutting edge as H rough And the radius of the ball head cutter is R, the contact height range of the rough machining cutting edge is [0 rough ]The contact height range of the finish machining cutting edge is [ H ] rough ，R]；
Step 3.2: defining the lateral inclination angle of the cutter as alpha, wherein the alpha represents the angle of the cutter in the direction away from the blade, and the lateral inclination angle corresponding to the upper limit of the available height of the rough cutting edge is
Further obtains the lateral inclination angle range of the rough machining tool path cutter shaft vector as
Side dip range of finish machining tool path cutter axis vector
Step 3.3: the tangents of the cutting contact point on the blade corresponding to the cutting contact point on the cutter cutting edge along the U and V directions of the blade are defined as tau respectively u ，τ v At τ u Is the vector initial direction of the cutter shaft, and is over-cut contact point P and parallel to tau v The straight line in the direction is used as the rotation axis, the rotation direction far away from the blade is used as the positive direction, and the corresponding rotation transformation is defined to be M α And obtaining the range of the rough machining cutter shaft vector L as follows:
the range of the finish machining cutter shaft vector L' is as follows:
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| CN114734079B (en) * | 2022-04-19 | 2023-12-26 | 中国航发动力股份有限公司 | Smooth transition processing method for milling joint of blade profile |
| CN114700539B (en) * | 2022-04-27 | 2023-07-18 | 西安三航动力科技有限公司 | Combined milling method for five-axis channels of blisk |
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