CN102794488B - Side milling processing method of resembled ruled surface integral wheel curved surfaces - Google Patents

Side milling processing method of resembled ruled surface integral wheel curved surfaces Download PDF

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CN102794488B
CN102794488B CN201210237109.8A CN201210237109A CN102794488B CN 102794488 B CN102794488 B CN 102794488B CN 201210237109 A CN201210237109 A CN 201210237109A CN 102794488 B CN102794488 B CN 102794488B
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cutter
ruled surface
ruled
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integral wheel
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CN102794488A (en
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毕庆贞
朱利民
王宇晗
丁汉
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Shanghai Jiaotong University
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Abstract

The invention relates to a side milling processing method of resembled ruled surface integral wheel curved surfaces. The method comprises the following steps that: firstly, similar ruled surfaces is acquired according to the resembled ruled surface integral wheel curved surfaces, and a resembled ruled surface is expressed by adopting two border triple B splines; then position and gesture of dispersed cutters are acquired through a polarization and according to approximate ruled surfaces and cutter parameters, and an initial cutter path is obtained through B spline interpolation; then the distance between the resembled ruled surface and a cutter enveloping surface is calculated, a cuter path integral optimization model following error evaluation criterions is established, the maximum optimized geometrical error is compared with a predetermined processing accuracy, and whether the resembled ruled surface meets processing accuracy requirements after being performed with side milling is judged; and at last, if the maximum optimized geometrical error is smaller than the predetermined processing accuracy, an optimal cutter path is generated, and a cutter path document is output. The side milling processing method of resembled ruled surface integral wheel curved surfaces overcomes the problem that the existing side milling processing method is only suitable for ruled surface blades, and expands application range of side milling process.

Description

The Flank machining method of class ruled surface integral wheel curved surface
Technical field
The present invention relates to a kind of Flank machining method, particularly relate to the Flank machining method of a kind ruled surface integral wheel curved surface.
Background technology
Five axle Flank machining refer to the side edge milling removal material with cutter, and compared with the Point contact machining mode of bulb end mill, Flank machining is line contact machining mode, and machined strip width significantly increases, and can improve material removing rate, can reduce the wearing and tearing of cutter.In addition, Flank machining also has the following advantages: because tool axis during Flank machining is basic parallel with spoon of blade, can avoid the interference of cutter and adjacent blades to greatest extent; Flank machining is that time processing is shaped, and can significantly improve the surface quality of processing parts.Flank machining is applicable to semifinishing and the fine finishining of monoblock type impeller blade curved surface very much, and the recommended highly-efficient processing for aviation parts.
Existing side milling cutter paths planning method for object often concentrate on ruled surface blade, for extended straight-line surface, adopt side milling mode can realize accurate processing; For non-extended straight-line surface, although adopt Flank machining to there is original reason error, also can obtain side milling cutter path by tool position optimization method, thus meet requirement on machining accuracy.But in actual applications, the spoon of blade of a lot of monoblock type impeller is not ruled surface, is generally class ruled surface, and current side milling cutter paths planning method inapplicable, this makes the scope of application of Flank machining receive greatly to limit.What is more important, and the class ruled surface of not all can be realized by Flank machining, therefore provide a kind of can the distinguishing rule of side milling most important.CAM software general at present does not provide this function for the Flank machining of class ruled surface, the MAX-PAC of Concepts NREC company is the Special CAD/CAM software for the processing of impeller five-shaft numerical control, and can also do not provide class ruled surface the distinguishing rule of side milling and tool paths generation strategy.
Through finding the literature search of prior art, Chinese Patent Application No. is: the patent of invention of 02139582 discloses a kind of drum-taper type cutter tool and the method with drum-taper type cutter tool side milling arbitrary surface centrifugal impeller, provide a kind of Flank machining method of free form surface, but this tool-path planning method is interfered for avoiding, adopt the strategy of multirow milling, greatly reduce the Flank machining efficiency of free form surface, and be difficult to the crudy ensureing integral wheel curved surface.In addition, application number is: the Chinese invention patent of 201110077039 again discloses a kind of five axle Flank machining parameters design methods, the method is optimized Flank machining technological parameter, but the processing object of the method is only confined to ruled surface, do not relate to the tool-path planning method of class ruled surface.
Summary of the invention
For the deficiency that above-mentioned prior art exists, the object of the present invention is to provide the Flank machining method of a kind ruled surface integral wheel curved surface, the method effectively can solve the problem that current Flank machining method is only applicable to ruled surface blade, greatly improves the applicability of existing Flank machining.
For achieving the above object, the invention provides the Flank machining method of a kind ruled surface integral wheel curved surface, comprising the following steps:
(1) according to class ruled surface integral wheel curved surface, obtain approximate ruled surface based on least square principle, and approximate ruled surface adopts two border B-spline Curve to represent;
(2) according to the approximate ruled surface obtained and given cutter parameters, obtain discrete tool position and attitude by biasing means, and obtain initial tool path by B-spline curves interpolation;
(3) compute classes ruled surface is to the distance of cutter enveloping surface, sets up the cutter path global optimization model following error criteria, the maximum geometrical deviation after being optimized;
(4) the maximum geometrical deviation after optimization and predetermined machining accuracy are compared, judge that can class ruled surface reach requirement on machining accuracy by side milling, if the maximum geometrical deviation after optimizing is less than predetermined machining accuracy, then such ruled surface reaches requirement on machining accuracy by side milling, generate optimum cutter path, export toolpath file; Otherwise if the maximum geometrical deviation after optimizing is greater than predetermined machining accuracy, then such ruled surface can not side milling.
According to the Flank machining method of the class ruled surface integral wheel curved surface described in present pre-ferred embodiments, such ruled surface is three-dimensional surface model or surface points cloud data file, and approaches class ruled surface discrete point cloud under two border B-spline Curve least square meanings.
According to the Flank machining method of the class ruled surface integral wheel curved surface described in present pre-ferred embodiments, this initial tool path is a ruled surface, adopts cutter shaft track plane to represent, the concrete following formula that adopts represents:
S ( w ; a , t ) = ( 1 - a ) P ( t ) + aQ ( t ) = Σ i = 0 l [ ( 1 - a ) N i , k ( t ) b i + aN i , k ( t ) d i ] ;
Wherein,
P (t) and Q (t) represents two border B-spline Curve;
N i,kt basic function that () is B-spline curves;
K is the exponent number of B-spline curves;
W t=[b 0 t..., b l t, d 0 t..., d l t] ∈ 6 (l+1), b 0..., b land d 0..., d lbe respectively the control point of two B-spline curves, i.e. the shape parameters in axis face;
L+1 is B-spline node number;
A, t are Surface Parameters, and (a, t) ∈ [0,1] × [t 0, t 1];
T 0it is initial parameters; t 1it is terminal parameter.
According to the Flank machining method of the class ruled surface integral wheel curved surface described in present pre-ferred embodiments, this cutter path global optimization model adopts following formula to represent:
min max 1 ≤ i ≤ n | d p i , X s ( w ) | ;
Wherein, X (w) represents the envelope surface of tool space motion generation; { p i3, the sampled point on 1≤i≤n} representation class ruled surface, n is the number of sampled point, 3it is three dimensional euclidean space; the distance of sampled point to cutter enveloping surface, the ultimate range of class ruled surface to enveloping surface;
According to the Flank machining method of the class ruled surface integral wheel curved surface described in present pre-ferred embodiments, the maximum geometrical deviation after this optimization is the maximum of geometrical deviation between class ruled surface and cutter envelope surface after optimizing.
According to the Flank machining method of the class ruled surface integral wheel curved surface described in present pre-ferred embodiments, this optimum cutter path is under the prerequisite meeting machining accuracy, by the optimal solution of cutter path global optimization problem as the cutter shaft track plane at control point; The cutter location file of toolpath file corresponding to post processor, specifically describes position and the direction of cutter.
According to the Flank machining method of the class ruled surface integral wheel curved surface described in present pre-ferred embodiments, this side milling cutter adopts any rotating tool, specifically can adopt cylindrical cutter, circular cone cutter or drum knife.
More than comprehensive, the present invention devises can class ruled surface reach requirement on machining accuracy distinguishing rule by side milling, and give high-quality cutter path by cutter path overall optimized algorithm, be namely applicable to class ruled surface threedimensional model, be also applicable to cloud data file.Therefore, compared with prior art, the Flank machining method of class ruled surface integral wheel curved surface of the present invention overcomes the problem that current Flank machining method is only applicable to ruled surface blade, five axle Flank machining tool-path planning of class ruled surface integral wheel curved surface can be applied to, greatly improve the applicability of existing Flank machining, greatly extend the scope of application of Flank machining.Further, computational efficiency is high, and all processes can complete automatically, realizes simple.
Accompanying drawing explanation
Fig. 1 is the process principle figure of the Flank machining method of class ruled surface integral wheel curved surface of the present invention;
Fig. 2 is the discrete point cloud schematic diagram of the class ruled surface Integral impeller blade curved surface of the embodiment of the present invention;
The class ruled surface Integral impeller blade surface model schematic diagram of Fig. 3 embodiment of the present invention;
The approximate ruled surface of the least square fitting acquisition of Fig. 4 embodiment of the present invention and straight edge line schematic diagram thereof;
The circular cone cutter of Fig. 5 embodiment of the present invention and the schematic diagram of parameter thereof;
The biasing means of Fig. 6 embodiment of the present invention generates the schematic diagram in initial tool path;
Worst error statistical chart after the every single-step iteration of cutter path global optimization of Fig. 7 embodiment of the present invention;
Class ruled surface Flank machining geometrical deviation distribution map after the optimization of Fig. 8 embodiment of the present invention;
The schematic diagram of tool motion profile after the optimization of Fig. 9 embodiment of the present invention.
Detailed description of the invention
Below in conjunction with accompanying drawing, illustrate the present invention.
Refer to Fig. 1, the Flank machining method of a kind ruled surface integral wheel curved surface, comprises the following steps:
(1) according to class ruled surface integral wheel curved surface, obtain approximate ruled surface based on least square principle, and approximate ruled surface adopts two border B-spline Curve to represent.
Class ruled surface can be three-dimensional surface model or surface points cloud data file, and approaches class ruled surface discrete point cloud under two border B-spline Curve least square meanings.
(2) according to the approximate ruled surface obtained and given cutter parameters, obtain discrete tool position and attitude by biasing means, and obtain initial tool path by B-spline curves interpolation.
Cutter parameters is the geometric parameter of cutter selected by Flank machining.The method is applicable to the rotating tool of any type, as cylindrical cutter, circular cone cutter or drum knife.For cylindrical cutter, tool radius and height need be provided; For circular cone cutter, radius of circle at the bottom of cutter, semi-cone angle and height need be provided.
Initial tool path, by the biased acquisition of approximate ruled surface, namely at straight edge line two-end-point place along curved surface normal bias one tool radius.This initial tool path cutter shaft track plane is expressed, and is a ruled surface.As shown in formula (1), cutter shaft track plane is represented by two borders B-spline Curve P (t) and Q (t), wherein N i,ku basic function that () is B-spline curves, w t=[b 0 t..., b l t, d 0 t..., d l t] ∈ 6 (l+1), b 0..., b land d 0..., d lbe respectively the control point of two B-spline curves, the shape parameters in axis face can be considered as; A, t are Surface Parameters, and (a, t) ∈ [0,1] × [t 0, t 1].
S ( w ; a , t ) = ( 1 - a ) P ( t ) + aQ ( t ) = Σ i = 0 l [ ( 1 - a ) N i , k ( t ) b i + aN i , k ( t ) d i ] - - - ( 1 )
(3) point of application-cutter Enveloped surface method, to error function compute classes ruled surface to the distance of cutter enveloping surface, sets up the cutter path global optimization model following error criteria, the maximum geometrical deviation after being optimized.
Point-cutter Enveloped surface method is defined to error function by formula (2), and wherein p is the discrete point on class ruled surface, and X is the envelope surface that tool motion is formed, S (w; A, t) be cutter shaft track plane, r (w; A, t) be tool radius.This function about the first differential increment of its shape parameters w as shown in formula (3).
d p , X s ( w ) = min ( a , t ) | | p - S ( w ; a , t ) | | - r ( w ; a , t ) - - - ( 2 )
Cutter path global optimization model, the point cloud data { p that envelope surface X (w) that can be summed up as tool space motion generation obtains after class ruled surface discretization i3, the best uniformity approximation problem of 1≤i≤n}, as shown in formula (4), this optimization problem is also referred to as extreme difference minimization problem or Chebyshev approximation problem
min w ∈ R 6 ( l + 1 ) max 1 ≤ i ≤ n | d p i , X s ( w ) | - - - ( 4 )
Introduce slack variable ξ, above-mentioned non-differentiability unconstrained optimization problem is converted into as follows can micro-constrained optimization problem
(5)
s . t . - ξ ≤ d p i , X s ( w ) ≤ ξ , 1 ≤ i ≤ n
Sequence linear programming algorithm is a kind of method conventional when solving constrained optimization problem, its basic ideas are by object function and constraint function Taylor expansion at current Xie Chu, retain linear term, then solve approximate linear programming problem and obtain a new solution, so iterate until restrain.If (w k, ξ k) be current solution, the feasible solution near it is designated as (w k+ Δ w, ξ k+ Δ ξ).Note v i=(S-p i)/|| S-p i||, obtain corresponding linear programming problem thus:
Maximum geometrical deviation after optimization, for optimizing the maximum of geometrical deviation between rear class ruled surface and cutter envelope surface.
(4) the maximum geometrical deviation after just optimizing and predetermined machining accuracy compare, judge that can class ruled surface reach requirement on machining accuracy by side milling, if the maximum geometrical deviation after optimizing is less than predetermined machining accuracy, then such ruled surface reaches requirement on machining accuracy by side milling, generate optimum cutter path, export toolpath file; Otherwise if the maximum geometrical deviation after optimizing is greater than predetermined machining accuracy, then such ruled surface can not side milling.
Concrete, above-mentioned optimum cutter path, refers under the prerequisite meeting machining accuracy, by the optimal solution of cutter path global optimization problem as the cutter shaft track plane at control point.Toolpath file, is and the cutter location file corresponding to post processor, describes position and the direction of cutter.
Below for circular cone cutter Flank machining class ruled surface integral wheel curved surface, composition graphs 2 to Fig. 9 illustrate based on best uniformity approximation can side milling differentiation and tool-path planning method, for class ruled surface integral wheel curved surface cooks up high-quality cutter path.But it should be noted that, method of the present invention is also applicable to the tool-path planning of other type side milling cutter such as cylindrical cutter, drum knife.In addition, factor data amount is comparatively large, and following examples only provide the data relevant to mismachining tolerance.
As shown in Figure 2, it is the discrete point cloud schematic diagram of the class ruled surface Integral impeller blade curved surface of the embodiment of the present invention.The class ruled surface integral wheel surface points cloud of the present embodiment has 85 × 7=595 some composition, these clouds also can be preserved by data file, and the class ruled surface that the present invention relates to is not limited to cloud data, is equally applicable to three-dimensional surface model, as shown in Figure 3.In the present embodiment, according to requirement on machining accuracy, permission mismachining tolerance is 0.05mm, and therefore, for this example, if the maximum geometric error after tool paths optimization is less than 0.05mm, then such ruled surface can side milling, otherwise can not side milling.
In the Flank machining of integral wheel class part, the minor radius that circular cone cutter can realize end under the prerequisite ensureing rigidity is cut, thus avoid the interference of cutter ends and workpiece and the difficulty of minor radius post cutter rigidity deficiency, therefore the present embodiment adopts circular cone cutter to carry out the Flank machining of class ruled surface blade, cutter parameters as shown in Figure 4, its end radius of circle is 3mm, and semi-cone angle is 5 °, is highly 30mm.The present invention is equally applicable to the side milling cutter of other type, as cylindrical cutter, drum knife etc.
To given class ruled surface integral wheel surface points cloud, first ruled surface matching is carried out based on least square principle, the ruled surface obtained and bus thereof are as shown in Figure 5, this ruled surface two boundary wire are expressed as the form of B-spline Curve, its knot vector is uniformly distributed, and respectively have 32 control points, factor data amount is comparatively large, and the present embodiment does not specifically provide these data.
As shown in Figure 6, on two borders of approximate ruled surface, respectively along Surface Method to offset or dish r 1and r 2, obtain initial discrete tool axis, and interpolation obtains two B-spline Curve, forms initial cutter shaft track plane by these two curves as boundary wire.In the present embodiment, offset or dish offset or dish r 2except except radius of circle at the bottom of cutter is relevant with semi-cone angle, also relevant with the straight edge line length of approximate ruled surface, its geometrical relationship can be tried to achieve with reference to figure 6.
Set up cutter path global optimization model according to formula (4), and application sequence linear programming relax solves this optimization problem.In solution procedure, the normal error of point-cutter enveloping surface and the calculating of First-order Gradient thereof are respectively with reference to formula (2) and (3).In each step iteration optimization, class ruled surface discrete point cloud to cutter envelope surface maximum geometrical deviation as shown in Figure 7, this value is reduced to the 0.234mm after optimization by the 0.676mm before optimizing, this value is less than given permission mismachining tolerance 0.05mm, this shows that such ruled surface can side milling, and after optimizing, the distribution of class ruled surface Flank machining geometrical deviation as shown in Figure 8.
According to the cutter shaft track plane after optimization, obtain a series of cutter position of cusp and cutter shaft unit vector through discrete, and export as cutter location data file, after optimizing, tool motion profile as shown in Figure 9, and this figure is only schematic diagram, therefore only gives 9 positions wherein.
The present invention devises can class ruled surface reach requirement on machining accuracy distinguishing rule by side milling, and gives high-quality cutter path by cutter path overall optimized algorithm, is namely applicable to class ruled surface threedimensional model, is also applicable to cloud data file.Therefore, compared with prior art, the Flank machining method of class ruled surface integral wheel curved surface of the present invention overcomes the problem that current Flank machining method is only applicable to ruled surface blade, five axle Flank machining tool-path planning of class ruled surface integral wheel curved surface can be applied to, greatly improve the applicability of existing Flank machining, greatly extend the scope of application of Flank machining.Further, computational efficiency is high, and all processes can complete automatically, realizes simple.
The above, it is only better embodiment of the present invention, not any pro forma restriction is done to the present invention, any content not departing from technical solution of the present invention, the any simple modification done above embodiment according to technical spirit of the present invention, equivalent variations and modification, all belong to the scope of technical solution of the present invention.

Claims (6)

1. the Flank machining method of a kind ruled surface integral wheel curved surface, is characterized in that, comprise the following steps:
(1) according to class ruled surface integral wheel curved surface, approximate ruled surface is obtained based on least square principle, described approximate ruled surface adopts two border B-spline Curve to represent, and described class ruled surface is three-dimensional surface model or surface points cloud data file, under described two border B-spline Curve least square meanings, approach class ruled surface discrete point cloud;
(2) according to the approximate ruled surface obtained and given cutter parameters, obtain discrete tool position and attitude by biasing means, and obtain initial tool path by B-spline curves interpolation;
(3) compute classes ruled surface is to the distance of cutter enveloping surface, sets up the cutter path global optimization model following error criteria, the maximum geometrical deviation after being optimized;
(4) the maximum geometrical deviation after optimization and predetermined machining accuracy are compared, judge that can class ruled surface reach requirement on machining accuracy by side milling, if the maximum geometrical deviation after optimizing is less than predetermined machining accuracy, then such ruled surface reaches requirement on machining accuracy by side milling, generate optimum cutter path, export toolpath file; Otherwise if the maximum geometrical deviation after optimizing is greater than predetermined machining accuracy, then such ruled surface can not side milling.
2. the Flank machining method of class ruled surface integral wheel curved surface as claimed in claim 1, it is characterized in that, described initial tool path is a ruled surface, adopts cutter shaft track plane to represent, the concrete following formula that adopts represents:
S ( w ; a , t ) = ( 1 - a ) P ( t ) + aQ ( t ) = Σ i = 0 l [ ( 1 - a ) N i , k ( t ) b i + a N i , k ( t ) d i ] ;
Wherein,
P (t) and Q (t) represents two border B-spline Curve;
N i,kt basic function that () is B-spline curves;
K is the exponent number of B-spline curves;
W t=[b 0 t..., b l t, d 0 t..., d l t] ∈ R 6 (l+1), b 0..., b land d 0..., d lbe respectively the control point of two B-spline curves, i.e. the shape parameters in axis face;
L+1 is B-spline node number;
A, t are Surface Parameters, and (a, t) ∈ [0,1] × [t 0, t 1];
T 0it is initial parameters; t 1it is terminal parameter.
3. the Flank machining method of class ruled surface integral wheel curved surface as claimed in claim 1, is characterized in that, described cutter path global optimization model adopts following formula to represent:
min max 1 ≤ i ≤ n | d p i , X s ( w ) | ;
Wherein, X (w) represents the envelope surface of tool space motion generation; { p i∈ R 3, the sampled point on 1≤i≤n} representation class ruled surface, n is the number of sampled point, R 3it is three dimensional euclidean space; the distance of sampled point to cutter enveloping surface, the ultimate range of class ruled surface to enveloping surface.
4. the Flank machining method of class ruled surface integral wheel curved surface as claimed in claim 1, is characterized in that, the maximum geometrical deviation after described optimization is the maximum of geometrical deviation between class ruled surface and cutter envelope surface after optimizing.
5. the Flank machining method of class ruled surface integral wheel curved surface as claimed in claim 1, it is characterized in that, described optimum cutter path is under the prerequisite meeting machining accuracy, by the optimal solution of cutter path global optimization problem as the cutter shaft track plane at control point; The cutter location file of described toolpath file corresponding to post processor, specifically describes position and the direction of cutter.
6. the Flank machining method of class ruled surface integral wheel curved surface as claimed in claim 1, described cutter adopts any rotating tool, specifically can adopt cylindrical cutter, circular cone cutter or drum knife.
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