CN114217570B - Method for generating efficient machining tool path with five-axis corner characteristics - Google Patents
Method for generating efficient machining tool path with five-axis corner characteristics 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
- G05B19/19—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 positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
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Abstract
The invention relates to the field of numerical control machining of parts, in particular to a method for generating a five-axis corner characteristic efficient machining tool path. And the cutting state optimization of the five-axis corner machining is realized by controlling the cutter shaft vector and the equivalent cutting width of the cutter during the five-axis corner machining. Firstly, calculating a cutter shaft vector according to a corner side surface, and then obtaining a tool path driving geometry of a five-axis corner according to the geometric parameters, the corner depth and the axial cutting depth of a cutter; and determining the maximum equivalent cutting width of the current cutter according to the performance of the processing machine tool and the information of the processing cutter, and generating a processing tool path with five-axis corner characteristics in the groove cavity by adopting a circular processing strategy. The five-axis corner machining tool path provided by the invention can be suitable for five-axis corner machining with various planes or equivalent planes on the side surfaces, and can effectively improve the machining quality of corners.
Description
Technical Field
The invention relates to the field of numerical control machining of parts, in particular to a method for generating a five-axis corner characteristic efficient machining tool path.
Background
In recent years, due to the improvement of the performance of aviation equipment and the requirements of integration and light weight, a large number of grooves exist in an aviation structural part for reducing the weight of parts, the rigidity and the strength of the structure are ensured at the same time, and corner features are used as transition features of the side surfaces which are mutually connected in the grooves and are important components of the grooves, so that the defect that edges cannot be machined in the direct connection areas of the two side surfaces can be overcome, and stress concentration is eliminated at the same time. The corner features have the defects of large cutting allowance change, large cutting force, flutter of a processing system and the like in the numerical control processing process. Meanwhile, due to large change of cutting allowance, problems of cutter back-off, cutter bouncing, even breakage and the like are easy to occur during corner machining, so that quality problems of parts are caused.
In order to reduce the defects of large cutting force, cutter back-off and the like in the corner characteristic machining process and avoid the quality problem of parts, the conventional method adopts conservative cutting parameters, multi-layer machining or a mode of removing large allowance by plunge milling and then finish machining. The machining efficiency of parts is seriously influenced by adopting conservative cutting parameters and multi-layer machining. When the plunge milling mode is adopted for machining, on one hand, the process programming difficulty is high, a plurality of plunge milling cutters are needed to be matched for completion, on the other hand, the milling cutter is finally needed for finish machining, and the defects of low corner machining efficiency and poor quality stability are not overcome. Aiming at the machining problem of the corner characteristic in the slot cavity of the aeronautical structural part, a three-axis corner characteristic machining process or a five-axis corner characteristic machining process is adopted in the prior art to solve the problems, such as:
the invention discloses a Chinese patent publication No. CN109725593B, and discloses a method for efficiently processing a three-axis corner feature of a difficult-to-process material, which aims at the problem that the cutting force is large in the corner processing of the difficult-to-process material, so that accidents such as tool tipping, tool bouncing, broach and the like are easily caused, and realizes the cutting force optimization of the corner processing by controlling the equivalent cutting width of the tool in the corner processing. Firstly, solving the corner machining drive geometry according to the axial cutting depth; and determining the maximum equivalent cutting width of the cutter according to the machining cutter and the machine tool, and generating a corner machining tool path by adopting a circulating milling strategy. The method can only be suitable for milling the side edge of the three-axis corner feature of which the side surface or the corner surface axis is vertical to the bottom surface of the part, but cannot be suitable for the five-axis corner feature of which the side surface or the corner surface axis is not vertical to the bottom surface, and the angle value of the side surface or the corner surface axis and the bottom surface of the five-axis corner feature in the engineering is arbitrary and is vertical only in a special case. It follows that this method has great limitations.
The Chinese patent with the publication number of CN102629289B discloses an automatic generation method of corner feature plunge milling tool paths, which aims at the requirement of five-axis corner feature plunge milling, and automatically calculates two control points of each tool path in the corner feature plunge milling process based on five-axis corner features to realize the generation of the corner feature plunge milling tool paths so as to achieve the purpose of corner plunge milling. The method discussed by the method aims at the plunge milling mode and cannot be applied to the side milling mode.
Disclosure of Invention
The invention aims to provide an efficient machining tool path generation method for five-axis corner features, which aims to solve the problems of large cutting allowance change, large cutting force, flutter of a machining system and the like in the numerical control machining process of the corner features in a slot cavity of an aeronautical structural member and solves the problems of low machining efficiency, complex programming and the like of a traditional method, so that the defects of cutting force, tool relieving and the like in five-axis corner machining can be effectively reduced, the machining efficiency is improved, and the quality problem of parts is avoided.
In order to achieve the above purpose, the invention provides the following specific technical scheme:
a method for generating a five-axis corner characteristic efficient machining tool path comprises the following steps:
s1, obtaining part corner characteristic information including corner surface, corner radius, corner surface, side normal vector, corner top surface, corner bottom surface and current allowance radius R of cornerCoarse；
S2, calculating to obtain a cutter shaft vector of the current corner according to normal vectors of two corner surfaces based on a machining coordinate system of part corner numerical control machining;
s3, determining the maximum equivalent cut width epsilon in the five-axis corner feature machining according to the material attribute, the machine tool performance and the machining tool structure information of the current five-axis corner feature;
s4, setting the diameter and the radius of the base angle of the cutter, calculating the offset value of each layer of equivalent bottom surface and cutting depth bottom surface of the five-axis corner according to the cutter axis vector, and creating an equivalent bottom surface;
s5, creating an equivalent triaxial plane perpendicular to the cutter shaft vector through the intersection point of the intersection line of the corner surface and any corner surface and the equivalent bottom surface, and performing Boolean intersection on the equivalent triaxial plane, the corner surface and the corner surface to obtain a drive line of an equivalent triaxial corner;
s6, calculating the radial machining tool path of one layer of the equivalent triaxial corner by taking the equivalent triaxial corner driving line obtained in the step S5 and the maximum equivalent cut width epsilon determined in the step S3 as input characteristics;
s7, projecting the radial processing tool path of the current layer of the equivalent three-axis corner obtained in the step 6 to the equivalent bottom surface created in the step S4 along the straight line where the tool axis vector is located;
s8, creating the bottom surface of each layer with different axial heights according to the axial cutting depth, repeating the operation of the steps S4-S7, calculating to obtain the equivalent bottom surface of each layer, and obtaining the machining tool path of each axial layer with five-axis corner characteristics;
and S9, arranging arc advancing and retracting cutters on each layer of cutter rails, and finally forming the high-efficiency machining cutter rail with the five-axis corner characteristic in the groove cavity of the aviation structural component.
Preferably, in the step S4, the offset value between the equivalent bottom surface and the cut bottom surface of each layer
Wherein d is the diameter of the cutter, r is the radius of the bottom angle, and theta is the included angle between the cutter shaft and the bottom surface of the cutting depth.
Preferably, in step S3, the material property is a material type of the workpiece to be machined, and the material type of the workpiece to be machined belongs to a hard metal material, including an aluminum alloy and a titanium alloy.
Preferably, in step S3, the machine tool performance includes a machine tool type, a spindle maximum rotation speed, and a use rotation speed; wherein the machine tool is a five-coordinate high-speed gantry, the maximum rotating speed of a main shaft of the machine tool is 6000 r/min-240000 r/min, and the using rotating speed is 2200 r/min-20000 r/min.
Preferably, in the step S3, the processing tool structure information includes the number of teeth of the tool and the diameter of the tool, the number of teeth of the tool is 2 to 4, and the diameter of the tool is 10 to 16 mm.
Preferably, in the step S3, the maximum equivalent cut width ∈ has a value range of 1 to 5 mm.
Preferably, in step S6, the step of calculating the radial machining tool path of the equivalent three-axis corner layer includes the following steps:
s6-1, determining the machining drive geometry of the corner radial layer based on the equivalent triaxial corner drive line;
s6-2, calculating tangential vectors at two end points of an intersection line of an equivalent triaxial plane and a corner plane based on the equivalent triaxial corner drive line, obtaining an intersection point of two tangent vectors along the opposite directions of the tangent vectors, setting the intersection point as an original point, and establishing a local coordinate system by taking one of normal vectors as an X axis;
s6-3, setting a corner characteristic theoretical radius RL as a current corner radius value R, and sequentially calculating a corner radial layer machining tool path from inside to outside, wherein the theoretical radius RL is the corner radius in the step S1;
s6-4, setting the end point of the section line of the corner surface in the corner radial layer processing driving geometry as a current corner allowance point, calculating tangent vector included angles at the two end points, and setting the included angle as a current corner included angle alpha;
s6-5, adopting an arc as a corner radial layer processing tool path, and calculating the radius of the previous radial layer tool path allowance arc satisfying the maximum equivalent width cutting principle according to the current corner included angle alpha, the radius R and the maximum equivalent width cutting epsilon;
s6-6, calculating an offset value mu-R/tan (alpha/2) according to the allowance circular arc radius of the previous radial layer cutter path calculated in the step S6-5, wherein R' is the allowance circular arc radius;
s6-7, geometrically solving the cut-in and cut-out point of the radial layer machining cutter according to the offset value mu in the corner radial layer machining drive solved in the step S6-1, so that the distance between the cut-in and cut-out point and a margin point which is geometrically corresponding to the current corner in the radial layer machining drive is mu; finally determining the allowance arc curve of the previous radial layer tool path according to the cut-in and cut-out point and the allowance arc radius;
s6-8, offsetting the cutter radius r' to the outer side of the corner by the cutter path allowance circular curve of the radial layer above the current corner obtained in the S6-7 to obtain a machining cutter path of the radial layer above the corner;
s6-9, carrying out coordinate transformation on the corner radial layer tool path under the local coordinate system to obtain a corner radial layer processing tool path under the part processing coordinate system;
s6-10, calculating a machining drive geometry intersection point of a radial layer tool path allowance circular arc curve on the corner obtained in S6-7 and the corner radial layer obtained in S6-1, and calculating a tangent vector of the drive geometry at the intersection point; calculating a tangent vector included angle alpha ' and a tangent vector intersection point O ', setting a geometric intersection point of a radial layer tool path allowance arc curve on the corner and a processing driving geometric intersection point of a radial layer of the corner as a current corner allowance point, setting alpha ' as a current corner included angle alpha, and setting a radial layer tool path allowance arc curve on the corner as a current corner radius;
s6-11, setting the point O' as an original point, and establishing a local coordinate system by taking a tangent vector calculated in the step S6-10 as an X axis;
s6-12, circulating from the step S6-5 to the step S6-11, calculating the machining tool paths of each layer in the radial direction of the corner in sequence until the allowance radius R of the tool path of the previous radial layer calculated in the step S6-5 is larger than or equal to the allowance radius RCoarse。
Preferably, in the step S6-5, the calculation of the measurement arc radius is to calculate the allowance arc radius of the radial layer of tool path on the corner respectively for two situations that the position where the equivalent cutting width of the tool is the largest occurs at the tool entry point or the tool axis is located at the corner angle bisector in the corner machining process, and the smaller value is the allowance arc radius of the radial layer of tool path on the corner.
The invention has the following beneficial effects:
the high-efficiency machining tool path with the five-axis corner characteristics, which is provided by the invention, can be suitable for high-efficiency machining of five-axis corners with various corner side surfaces being planes or equivalent triaxial planes. By controlling the cutter shaft vector and the equivalent cutting width of the cutter during five-axis corner machining, the cutting state optimization of five-axis corner machining is realized, the cutting force and the vibration of a machining system are reduced, meanwhile, the cutter abrasion is reduced, and the problems of cutter back-off, cutter bouncing and the like are avoided, so that the quality problem of parts is avoided, and the machining efficiency and the machining quality of five-axis corners in the groove cavity are effectively improved.
Drawings
FIG. 1 is a schematic diagram of a typical five-axis corner feature;
FIG. 2 is a schematic diagram illustrating calculation of an equivalent bottom surface of a current axial machining layer, where d is a diameter of a tool, r is a radius of a bottom angle of the tool, θ is an included angle between an axial direction of the tool and the bottom surface, and L is an offset of the equivalent bottom surface;
FIG. 3 is a schematic diagram of the maximum equivalent cutting width of the tool at the bisector of the corner angle, where d is the diameter of the tool, R1 and R2 are the radii of the arc between the current machining layer and the previous layer, and ε is the maximum equivalent cutting width of the tool;
FIG. 4 is a geometric diagram of a driving line of a current layer equivalent triaxial corner of a five-axis corner feature;
FIG. 5 is an enlarged view of the structure at B in FIG. 4;
FIG. 6 is a schematic diagram of a typical five-axis corner feature efficient machining tool path;
FIG. 7 is an enlarged view of the structure at A in FIG. 6;
in the figure:
1. a corner surface; 2. a corner side surface; 3. a corner top surface; 4. a corner bottom surface; 5. cutting the bottom surface deeply; 6. an equivalent bottom surface; 7. equivalent triaxial corner driving wires; 8. a point of intersection; 9. an equivalent triaxial plane; 10. retracting the tool path; 11. equivalent triaxial corner is obtained when the current layer radial tool path is formed; 12. a current layer five-axis corner radial tool path; 12.1, a first layer of tool paths; 12.2, a second layer of tool paths; 12.3, a third layer of tool paths; 12.4, starting point; 12.5, end point; 13. a cutter shaft; 14. and feeding a tool path.
Detailed Description
The invention is further described in the following with reference to the drawings and examples, but it should not be understood that the invention is limited to the examples below, and variations and modifications in the field of the invention are intended to be included within the scope of the appended claims without departing from the spirit of the invention.
The embodiment discloses a method for generating a tool path for efficient machining of five-axis corner features, and as a preferred embodiment of the invention, a typical five-axis corner feature shown in fig. 1 is taken as an example to explain an algorithm flow for generating a tool path for efficient machining of a difficult-to-machine material. The corner radius is 6mm, and a cutter with the diameter of phi 10mm and the base angle radius of 3mm is selected for processing.
The five-axis corner in the structural member slot cavity has the following structural characteristics and processing requirements:
the method comprises the following steps of (1) offsetting and obtaining the bottom surface of each layer according to the vector of a cutter shaft and the axial cutting depth (the axial cutting depth is determined according to process setting, is generally a number, has the bottom surface with the combination characteristics after cutting, and creates the cutting depth bottom surface 5 of each layer with different heights according to the axial cutting depth) and the radial cutting width during processing to realize layered processing, wherein the radial direction and the axial direction of a five-axis corner are both composed of multilayer tool tracks;
the radial layering of the corner needs to consider the constraint of a cutter shaft vector and the equivalent cut width. The equivalent cutting width is determined according to the selected machining tool, the selected part material and the selected machine tool performance;
the five-axis corner radial multilayer tool path consists of a plurality of curve tool paths, and corner allowance is removed for multiple times, so that the aim of controlling equivalent cutting width in five-axis corner processing is fulfilled;
the five-axis corner radial layer processing cutter shaft vector is a vector formed by normal vectors of planes on two sides of a corner.
Based on the structural characteristics and the processing requirements of the five-axis corner in the structural part groove cavity, the method for generating the efficient processing tool path of the five-axis corner characteristics comprises the following steps:
s1, obtaining part corner characteristic information, including a corner surface 1, a corner radius, corner side surfaces 2, side surface normal vectors, a corner top surface 3 and a corner bottom surface 4, wherein the corner radius R is 6mm, the normal vector of one corner side surface 2 is (0,0.9823, -0.187), the normal vector of the other corner side surface 2 is (0.9962, -0.8562, 0.0163), and the current allowance radius R of the corner after rough machining isCoarse＝11mm。
And S2, calculating to obtain a cutter shaft vector of the current five-axis corner feature machining according to normal vectors of the two corner side surfaces 2 based on a machining coordinate system of the part corner numerical control machining, wherein the cutter shaft vector is (0, 0.187, 0.9823).
S3, determining the maximum equivalent cut width epsilon in the five-axis corner feature machining according to the material attribute, the machine tool performance and the machining tool structure information of the current five-axis corner feature; wherein, the material attribute refers to the material type of the work piece that is processed, and this technical scheme mainly aims at the work piece of processing hard metal material, for example: different materials of the aluminum alloy and the titanium alloy have different rigidity strengths, and the higher the rigidity is, the larger the corresponding maximum equivalent shear width epsilon is; furthermore, the better the mechanical property of the numerical control machine tool and the cutting property of the cutter, the larger the maximum equivalent cutting width epsilon. The machine tool information comprises the type of the machine tool, the maximum rotating speed of the main shaft and the using rotating speed; wherein the machine tool type is a five-coordinate high-speed gantry, the maximum rotating speed of a main shaft of the machine tool is 6000 r/min-240000 r/min, and the using rotating speed is 2200 r/min-20000 r/min. The processing cutter structure information includes cutter number of teeth and cutter diameter, and the cutter number of teeth is 2 ~ 4, and the cutter diameter is 10 ~ 16 mm. The value range of the maximum equivalent cut width epsilon is 1-5 mm. Such as:
in the case of example 1, the following examples,
the type of material of the workpiece to be processed: an aluminum alloy;
machine tool performance: the five-coordinate high-speed gantry machine tool has the main shaft with the highest rotating speed of 24000r/min and the use rotating speed of 9000 r/min;
cutting performance of the cutter: the number of teeth is 2, and the diameter is 10 mm;
maximum equivalent cut width: 3 mm;
in the case of example 2, the following examples,
the type of material of the workpiece to be processed: an aluminum alloy;
machine tool performance: the five-coordinate high-speed gantry machine tool has the main shaft with the highest rotating speed of 24000r/min and the using rotating speed of 20000 r/min;
cutting performance of the cutter: the number of teeth is 2, and the diameter is 16 mm;
maximum equivalent cut width: 5 mm;
in the case of example 3, the following example was carried out,
the type of material of the workpiece to be processed: a titanium alloy;
machine tool performance: the maximum rotating speed of a main shaft of the five-coordinate high-speed gantry machine tool is 6000r/min, and the maximum rotating speed is 2400 r/min;
cutting performance of the cutter: the number of teeth is 4, and the diameter is 10 mm;
maximum equivalent cut width: 1 mm.
This example was carried out using the data of example 1 above.
S4, setting the diameter and the radius of a bottom angle of the cutter, calculating the offset value of each layer of equivalent bottom surface 6 and cutting depth bottom surface 5 of the five-axis corner according to the cutter axis vector, and creating the equivalent bottom surface 6; specifically, as shown in fig. 2, the offset between the equivalent bottom surface 6 and the cut-back bottom surface 5 of each layer is set
Where the tool diameter d is 10mm, the base angle radius r is 3mm, and the angle θ between the arbor 13 and the cutting bottom surface 5 is 75.22 °, L is calculated to be 0.427 mm.
And S5, creating an equivalent triaxial plane 9 perpendicular to the cutter shaft vector by using the intersection 8 of the intersection line of the corner surface 1 and any corner side surface 2 and the equivalent bottom surface 6, and performing Boolean intersection on the equivalent triaxial plane 9, the corner side surface 2 and the corner surface 1 to obtain a driving line of an equivalent triaxial corner.
S6, taking the equivalent three-axis corner driving line 7 obtained in step S5 and the maximum equivalent cutting width ∈ determined in step S3 as input features, and calculating a radial machining tool path of one layer of the equivalent three-axis corner (such as the current-layer radial tool path 11 of the equivalent three-axis corner presented in fig. 5), specifically including the following steps:
s6-1, as shown in FIG. 4, determining the corner radial layer processing drive geometry based on the equivalent triaxial corner drive line 7;
s6-2, calculating tangential vectors at two end points of an intersection line of the equivalent triaxial plane 9 and the corner surface 1 based on the equivalent triaxial corner driving line 7, obtaining an intersection point of two tangent vectors along the opposite directions of the tangent vectors, setting the intersection point as an origin, and establishing a local coordinate system by taking one of the normal vectors as an X axis;
s6-3, setting a corner characteristic theoretical radius RL as 6mm as a current corner radius value R, and sequentially calculating a corner radial layer processing tool path from inside to outside, wherein the theoretical radius RL is the corner radius in the step S1;
s6-4, setting the end point of the section line of the corner surface 1 in the corner radial layer machining drive geometry as a current corner allowance point, calculating tangent included angles at the two end points, and setting the included angle as a current corner included angle alpha equal to 85 degrees;
s6-5, in order to improve the calculation efficiency and avoid the linear interpolation of the machine tool, adopting an arc as a corner radial layer processing tool path, calculating the allowance arc radius of the last radial layer tool path which meets the principle of the maximum equivalent cutting width according to the current corner included angle alpha, the radius R and the maximum equivalent cutting width epsilon, namely, as shown in figure 3, calculating the allowance arc radius of the last radial layer tool path on the corner respectively aiming at two conditions that the position with the maximum equivalent cutting width of the cutter occurs at the cutting point of the cutter or the axis of the cutter is positioned at the bisector of the corner angle in the corner processing, and taking the smaller value as the allowance arc radius of the last radial layer tool path on the corner, wherein the specific calculation mode refers to the invention patent of a difficult-to-process material three-axis corner characteristic efficient processing tool path generation method, and the patent number is CN 201711036451.0. And calculating to obtain the radius of the allowance circular arc of the radial layer of tool path on the corner of 6.96 mm.
S6-6, calculating an offset value mu-1.05 mm according to the allowance circular arc radius of the previous radial layer cutter path calculated in S6-5, wherein R' is the allowance circular arc radius;
s6-7, geometrically solving the cut-in and cut-out point of the radial layer machining cutter according to the offset value mu in the corner radial layer machining drive solved in the step S6-1, so that the distance between the cut-in and cut-out point and a margin point which is geometrically corresponding to the current corner in the radial layer machining drive is 1.05 mm; finally determining a previous radial layer tool path allowance arc curve according to the cut-in and cut-out point and the allowance arc radius;
s6-8, offsetting the cutter radius r' to the outer side of the corner by the arc curve of the allowance of the cutter path of the radial layer on the current corner obtained in the S6-7 to be 5mm, and obtaining the processing cutter path of the radial layer on the corner;
s6-9, carrying out coordinate transformation on the corner radial layer tool path under the local coordinate system to obtain a corner radial layer processing tool path under the part processing coordinate system;
s6-10, calculating the intersection point of the radial layer tool path allowance circular arc curve on the corner obtained in S6-7 and the corner radial layer processing driving geometry obtained in S6-1, and calculating the tangent vector of the driving geometry at the intersection point; and calculating a tangent included angle alpha ' and a tangent intersection point O ', wherein alpha ' is 81 degrees. And setting a geometric intersection point of a tool path allowance circular arc curve of a radial layer on the corner and a machining driving geometric intersection point of the radial layer on the corner as a current corner allowance point, setting alpha' as a current corner included angle alpha, and setting the tool path allowance circular arc curve of the radial layer on the corner as a current corner radius.
S6-11, using the point O' as the origin, and using a tangent vector calculated in the step S6-10 as the X axis to establish a local coordinate system.
S6-12, circulating from S6-5 to S6-11, sequentially calculating the corner radial layer processing tool paths (shown in the schematic diagram of the current layer equivalent triaxial corner and five-axis corner efficient processing tool path shown in FIG. 5) until the radius of the allowance circular arc of the previous radial layer tool path calculated in S6-5 is larger than or equal to the allowance radius RCoarse. The calculated radial layer comprises 3 layers of tool paths, and the corresponding tool path allowance circular arcs are respectively 6mm, 6.96mm and 8.7 mm.
And S7, projecting the radial machining tool path of the equivalent three-axis corner current layer obtained in the step 6 onto the equivalent bottom surface 6 created in the step S4 along the straight line where the cutter axis vector is located, and laying a foundation for obtaining the five-axis corner radial tool path 12 of the current layer as shown in FIG. 5.
And S8, creating bottom surfaces of each layer with different axial heights according to the axial cutting depth, repeating the operations of the steps S4-S7, calculating to obtain the equivalent bottom surface 6 of each layer, and obtaining five-axis corner features, such as the first layer tool path 12.1, the second layer tool path 12.2 and the third layer tool path 12.3 shown in the figure 7.
And S9, arranging arc advancing and retracting cutters (namely, as shown in FIG. 6, arranging the cutter feeding tracks 14 and the cutter retracting tracks 10 based on the starting points 12.4 and the end points 12.5 of the current layer five-axis corner radial cutter tracks 12) for each layer of cutter track, and finally forming the high-efficiency machining cutter track with the five-axis corner characteristic in the slot cavity of the aeronautical structure component, as shown in FIGS. 6 and 7.
Claims (7)
1. A method for generating a five-axis corner characteristic efficient machining tool path is characterized by comprising the following steps:
s1, obtaining part corner characteristic information including a corner surface (1), a corner radius, a corner side surface (2), a side normal vector, a corner top surface (3), a corner bottom surface and a current allowance radius R of a cornerCoarse；
S2, calculating to obtain a cutter shaft vector of the current corner according to the normal vectors of the two corner side surfaces (2) based on the machining coordinate system of the part corner numerical control machining;
s3, determining the maximum equivalent cut width epsilon in the five-axis corner feature machining according to the material attribute, the machine tool information and the machining cutter structure information of the current five-axis corner feature;
s4, setting the diameter and the radius of the base angle of the cutter, calculating the offset value of each layer of equivalent bottom surface (6) and the cutting depth bottom surface (5) of the five-axis corner according to the cutter axis vector, and creating the equivalent bottom surface (6); offset value between the equivalent bottom surface (6) and the cutting depth bottom surface (5) of each layer
Wherein d is the diameter of the cutter, r is the radius of a base angle, and theta is the included angle between the cutter shaft (13) and the cutting depth bottom surface (5);
s5, creating an equivalent triaxial plane (9) perpendicular to a cutter shaft vector by using an intersection point (8) of an intersection line of the corner surface (1) and any corner side surface (2) and the equivalent bottom surface (6), and performing Boolean intersection on the equivalent triaxial plane (9), the corner side surface (2) and the corner surface (1) to obtain a driving line of an equivalent triaxial corner;
s6, calculating a radial machining tool path of one layer of the equivalent triaxial corner by taking the equivalent triaxial corner drive line (7) obtained in the step S5 and the maximum equivalent cutting width epsilon determined in the step S3 as input characteristics;
s7, projecting the radial processing tool path of the current layer of the equivalent three-axis corner obtained in the step 6 onto the equivalent bottom surface (6) created in the step S4 along the straight line where the tool axis vector is located;
s8, creating the bottom surface of each layer with different axial heights according to the axial cutting depth, repeating the operations of the step S4-S7, calculating to obtain the equivalent bottom surface (6) of each layer, and obtaining the machining tool path of each axial layer with five-axis corner characteristics;
and S9, arranging arc advancing and retracting cutters on each layer of cutter rails, and finally forming the high-efficiency machining cutter rail with the five-axis corner characteristic in the groove cavity of the aviation structural component.
2. The method for generating the five-axis corner feature efficient machining tool path as claimed in claim 1, wherein the method comprises the following steps: in step S3, the material property refers to the type of the workpiece to be machined, and the type of the workpiece to be machined belongs to hard metal materials, including aluminum alloys and titanium alloys.
3. The method for generating the five-axis corner feature efficient machining tool path as claimed in claim 1, wherein the method comprises the following steps: in step S3, the machine tool information includes a machine tool type, a maximum spindle rotation speed, and a use rotation speed; wherein the machine tool type is a five-coordinate high-speed gantry, the maximum rotating speed of a main shaft of the machine tool is 6000 r/min-240000 r/min, and the using rotating speed is 2200 r/min-20000 r/min.
4. The method for generating the five-axis corner feature efficient machining tool path as claimed in claim 1, wherein the method comprises the following steps: in step S3, the processing cutter structure information includes cutter number of teeth and cutter diameter, and cutter number of teeth is 2 ~ 4, and the cutter diameter is 10 ~ 16 mm.
5. The method for generating the five-axis corner feature efficient machining tool path as claimed in claim 1, wherein the method comprises the following steps: in the step S3, the maximum equivalent cut width epsilon ranges from 1mm to 5 mm.
6. The method for generating a five-axis corner feature efficient machining tool path as claimed in claim 1, wherein in the step S6, the step of calculating the radial machining tool path of the equivalent three-axis corner layer includes the following steps:
s6-1, determining the machining drive geometry of the corner radial layer based on the equivalent triaxial corner drive line (7);
s6-2, calculating tangential vectors at two end points of an intersection line of an equivalent triaxial plane (9) and a corner plane (1) based on an equivalent triaxial corner drive line (7), obtaining an intersection point of two tangent vectors along the opposite directions of the tangent vectors, setting the intersection point as an origin, and establishing a local coordinate system by taking one of the normal vectors as an X axis;
s6-3, setting the corner characteristic theoretical radius RL as the current corner radius value R, and sequentially calculating a corner radial layer processing tool path from inside to outside, wherein the theoretical radius RL is the corner radius in the step S1;
s6-4, setting the section line end point of the corner radial layer processing driving geometric corner surface (1) as a current corner allowance point, calculating tangent vector included angles at the two end points, and setting the included angle as a current corner included angle alpha;
s6-5, adopting an arc as a corner radial layer processing tool path, and calculating the radius of the previous radial layer tool path allowance arc satisfying the maximum equivalent cutting width principle according to the current corner included angle alpha, the radius R and the maximum equivalent cutting width epsilon;
s6-6, calculating an offset value mu-R/tan (alpha/2) according to the allowance circular arc radius of the previous radial layer cutter path calculated in the step S6-5, wherein R' is the allowance circular arc radius;
s6-7, geometrically solving the cut-in and cut-out point of the radial layer machining cutter according to the offset value mu in the corner radial layer machining drive solved in the step S6-1, so that the distance between the cut-in and cut-out point and a margin point which is geometrically corresponding to the current corner in the radial layer machining drive is mu; finally determining the allowance arc curve of the previous radial layer tool path according to the cut-in and cut-out point and the allowance arc radius;
s6-8, offsetting the cutter radius r' to the outer side of the corner by the cutter path allowance arc curve of the radial layer on the current corner obtained in the S6-7 to obtain a machining cutter path of the radial layer on the corner;
s6-9, carrying out coordinate transformation on the corner radial layer tool path under the local coordinate system to obtain a corner radial layer processing tool path under the part processing coordinate system;
s6-10, calculating a machining drive geometry intersection point of a radial layer tool path allowance circular arc curve on the corner obtained in S6-7 and the corner radial layer obtained in S6-1, and calculating a tangent vector of the drive geometry at the intersection point; calculating a tangent vector included angle alpha ' and a tangent vector intersection point O ', setting a geometric intersection point of a radial layer tool path allowance arc curve on a corner and a processing driving geometric intersection point of a radial layer of the corner as a current corner allowance point, setting alpha ' as a current corner included angle alpha, and setting a radial layer tool path allowance arc curve on the corner as a current corner radius;
s6-11, setting the point O' as an origin, and establishing a local coordinate system by taking a tangent vector calculated in the step S6-10 as an X axis;
s6-12, circulating from the step S6-5 to the step S6-11, calculating the machining tool paths of each layer in the radial direction of the corner in sequence until the allowance radius R of the tool path of the previous radial layer calculated in the step S6-5 is larger than or equal to the allowance radius RCoarse。
7. The method for generating a five-axis corner feature high-efficiency machining tool path as claimed in claim 6, wherein in step S6-5, the calculation of the margin arc radius is performed for two cases where the position where the equivalent cutting width of the tool is the largest occurs at the tool entry point or the tool axis is located at the corner bisector during the corner machining, and the margin arc radius of the tool path in a radial layer on the corner is calculated respectively, and the smaller value is the margin arc radius of the tool path in the radial layer on the corner.
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