CN102085576A - Five-axis linkage variable-axis plunge milling numerically controlled processing method for blade part of integral impeller - Google Patents

Abstract

The invention discloses a five-axis linkage variable-axis plunge milling numerically controlled processing method for a blade part of an integral impeller. The method comprises the following steps: 1) dividing a spatial free-form surface to be processed of a part into multiple areas to be processed; 2) analyzing the stress conditions in a tooling process; 3) selecting a proper plunge milling cutter; 4) planning a processing route; 5) generating a track of a numerically controlled cutter; 6) simulating by utilizing a numerically controlled program; 7) editing the numerically controlled program; and 8) processing the part. The method is characterized in that by adopting a five-axis linkage variable-axis plunge milling manner, the processing efficiency of removing large margin by virtue of rough grooving of the integral impeller is improved, and the processing problem that finishing process with a ball cutter is required as the residual margin on a blade surface is not uniform after the plunge milling of a fixed axle of the free-form surface is solved; and the method disclosed by the invention can be applied to the five-axis numerically controlled milling processing needing to remove large-margin parts of the complicated free-form surface structures such as axial-flow type integral impellers, integral blade rings and the like as well as to the multi-axis numerically controlled milling processing of the parts of simple free-form surface structures such as centrifugal type integral impellers, mould processing and the like.

Description

A kind of integral wheel blade-section five-axle linkage becomes the slotting numerical-control processing method that mills of axle

Technical field

The invention belongs to machinery manufacturing technology field, relate to a kind of processing method of machine components, particularly a kind of integral wheel blade-section five-axle linkage becomes the slotting numerical-control processing method that mills of axle.

Background technology

The integral wheel process technology is one of key technology of advanced aero-engine, the restriction that material property is influenced by special processing technology and machining accuracy etc. requires, and machining is still most widely used processing method; Blade-section is a complex free curved surface in the integral wheel, blade-section is forging molding directly, and therefore, the blank of integral wheel mostly is solid forging, this heightens with regard to having caused integral wheel clearance of material in process, and maximum material removal rate can reach more than 93 %.At present, the processing method of integral wheel adopts to bore more mills or displacement is inserted and milled thick fluting, because brill mills or slotting the milling of displacement belongs to the fixed axis processing mode, and the free form surface shape is comparatively complicated, therefore, owe to cut the position and owe the amount of cutting all very big, must adopt rose cutter or end R milling cutter point to mill method for processing and owe the amount of cutting with removal.Because this kind processing method processes at least twice, has increased by one times process time, data processing amount is big, and working (machining) efficiency is low.

Therefore in the thick fluting process of integral wheel, adopt which kind of cutter, use which kind of processing method, make that the finished surface surplus is more even,, improve working (machining) efficiency simultaneously for finish-milling processing provides safeguard, cut down finished cost, become the key of the thick fluting process technology of integral wheel.

Summary of the invention

The purpose of this invention is to provide a kind of integral wheel blade-section five-axle linkage and become the slotting numerical-control processing method that mills of axle, this numerical-control processing method has improved working (machining) efficiency, reduced production cost, also guaranteed finished surface surplus uniformity simultaneously, to improve the uniformity of finish-milling forming residual stress.

Technology of the present invention solves thinking, the displacement fixed axis is inserted the technology of milling further expand, and displacement is combined with slotting milling, and realizes inserting in the displacement process and mills function.

A kind of integral wheel blade-section of the present invention five-axle linkage change axle is inserted and is milled numerical-control processing method, carries out according to the following steps:

1) space free curved surface part is to be processed splits into a plurality of zones to be processed;

In each zone to be processed, guarantee that at curvature direction basically identical between cutting starting point and the terminating point on the Tool in Cutting direction cutter is in processing and cross on the direction curvature and change and be not more than 10 %;

2) stressing conditions in the analysis cutter process;

Because it is less to the tolerance degree of radial load to plug in milling cutter, therefore, must will insert the stress of the every bit of milling cutter in the five-axle linkage process analyzes clear, to guarantee the inserting radial load minimum that milling cutter is born in the process, also to consider the durability of inserting milling cutter tool fillet R position simultaneously;

3) select suitable plug in milling cutter;

According to step 1), 2) analyze, be to guarantee working (machining) efficiency, inserting the milling cutter diameter should not be too little, to consider simultaneously avoid cutting and the withdrawing process in knife bar grind with the collision of part, so must have stronger appearance to consider ability to be worth doing between blade, so the choice criteria cutter; In addition, according to the plug in milling cutter cutting edge characteristics at center only, the side of the Tool in Cutting direction of motion needs fluting in advance, does not have interference to guarantee the non-cutting of cutter position;

4) planning processing route;

According to the processing characteristic of plugging in milling cutter, cutter path step direction cutting depth should mode from deep to shallow be processed, and curved surface advances in the step direction upper edge, cutting width can change, in order to guarantee that non-cutting position does not bump with part, the cutting step pitch should be not more than 50 % of Tool in Cutting tread degree;

5) generate the NC cutting tool track;

Utilize UG(three-dimensional CAD design software) and MAX-PAC(turbo wheel digital control processing programming software bag) the multiaxis programing function of software, in selected cutting zone, set up and generate cutter path;

6) numerical control program emulation;

Whether the cutter path that generates is carried out the emulation of cutter path through nc machining simulation software, and check to exist in emulation and cut, owe to cut or cutter interference; Cut, owe to cut or cutter interference if having, execution in step 7); Do not cut, owe to cut or cutter interference if having, skips steps 7), direct execution in step 8);

7) editor's numerical control program;

Because cutting, owing to cut or cutter interference may appear in the cutter path that calculates of step 5), through the VERICUT(numerical control machining simulation system in the described step 6)) after software carries out machining simulation, find out and occurred cutting, owe to cut or the statement of cutter interference; If problem or program statement are more, complicated, then need readjust, calculation procedure, if problem is less or when simple, method is finely tuned by hand, because adjust A, the B axle is bigger to the influence of adjustment amount, only adjust the numerical value of X, Y, three linear axes of Z during general manual setting, adjustment amount is not more than 1mm usually, adjusts and jumps to step 6) after finishing; 8) processing parts;

Integral wheel blade-section five-axle linkage of the present invention becomes the slotting numerical-control processing method that mills of axle, solved the complex free space curved surface when the processing opening character is relatively poor, material is removed inefficient technical barrier in unit interval, improved working (machining) efficiency, reduce production cost, guaranteed finished surface surplus uniformity.

Description of drawings

Fig. 1 is the area schematic to be processed that the blade of integral wheel is divided into along the string cross direction

Fig. 2 a is that cutter is at the stress schematic diagram that blade is added man-hour

Fig. 2 b is the A partial enlarged drawing of Fig. 2 a

Fig. 3 is the step direction schematic diagram of milling cutter processing

Fig. 4 is a cutter machining locus schematic diagram

Among the figure 1,blade 2, regional 3,string cross direction 4 to be processed, cutter 5, step direction 6, cutter path.

The specific embodiment

Below in conjunction with the drawings and specific embodiments the present invention is described in further detail, but the present invention not only is confined to following examples.

Concrete size, material and the machined parameters of the integral wheel of present embodiment are as follows:

The maximum outside diameter of blade: 936mm;

The minimum outer diameter of blade: 482mm;

The largest chord of blade is wide: 210mm;

The number of blade: 20;

Blade tip maximum ga(u)ge: 4.5mm;

Blade root maximum ga(u)ge: 12.5mm;

Material: titanium alloy;

Machined parameters: processing line speed 30～40m/min;

Integral wheel blade-section five-axle linkage change axle of the present invention is inserted and is milled numerical-control processing method, carries out according to the following steps:

1) in Fig. 1, thewhole blade 1 of integral wheel is divided into some to be processed regional 2 along string cross direction 3;

2) press the stress of method labortypical case cutter 4 tracks of Fig. 2 a, Fig. 2 b at different parts;

3) according to step 1), 2) the selectedsuitable cutter 4 of analysis result, select theslotting milling cutter 4 of Φ 32mm diameter, blade width 10mm, blade fillet R1.2mm in the present case for use;

4) in Fig. 3, slot in advance in the side ofcutter 4 cutting movement directions, determine processing step direction 5 again;

5) utilize UG(three-dimensional CAD design software) and MAX-PAC(turbo wheel digital control processing programming software bag) the multiaxis programing function of software, in selected cutting zone, set up and generate cutter path 6, as described in Figure 4, because present case is a processing axial-flow type integral wheel, what use is SI (whole double shrouded wheel) the CAM functional module of the special-purpose MAX of impeller-PAC software, and its advantage is can parametrization at the machining area of processingintegral wheel blade 1 free form surface;Blade 1 part of integral wheel to be processed distortion is bigger in the present case, by calculating, when cutting depth is not more than 11mm, curvature changes less than 10 %, A, B axle change lessly in the five-axle linkage process, and Y, Z linear axes change greatly, meet plug in milling cutter force request;Blade 1 largest chord is wide to be 21Omm, calculates according to maximum depth of cut, is divided into 20 layers; For guaranteeing that plugging in milling cutter does not participate in radial cutting, after putting in place, cutter 4 working depths return along former road fast, and withdrawing crossessafe distance 1 mm and crosses to next bar cutter path 6 position and continue cutting;

6) cutter path 6 that generates is through VERICUT(nc machining simulation software) carry out the emulation of cutter path 6, and check in emulation, whether to exist and cut, owe to cut or cutter interference; Cut, owe to cut or cutter interference if having, execution in step 7); Do not cut, owe to cut or cutter interference if having, skips steps 7), direct execution in step 8);

The numerical control program that generates is as follows: % _ N _ AS90171

N0l0?G90?G94?G00?Z800.0?M3?S350

N0020?G01?X-324.76 Y590.68 Z702.25 A-34.969?B125.043?F20000?.

N0O21?Y41.92?Z318.45

N0022?Y3.41?Z291.51?F3000?.

N0023?Y.13?Z289.22?F100.?M07?M08

NO024?X-324.77?Y-.92?Z285.27?A-34.909?B124.544

N0025?X-324.86?Y-2.49?Z281.97?A34.867?B123.918

N0026?X-325.?Y-4.35?Z279.1?A-34.836?B123.222

N0027?X-324.86?Y-2.49?Z281.97?A-34.867?B123.918?F3000.

N0028?X-324.77?Y-92?Z285.27?A-34.909?B124.544

N0029?X-324.76?Y.13?Z289.22?A-34.969?B125.043

N0030?X-320.5?Y-1.62?Z292.44?A-35.305?B125.018?F500.

N0031?X-320.45?Y-2.13?Z287.69?A-35.223?B124.645?F100.

N0032?X-320.49?Y-3.32?Z283.82?A-35.164?B124.104

N0033?X-320.6?Y-4.94?Z280.55?A-35.121?B123.464

N0034?X-320.49?Y-3.32?Z283.82?A-35.164?B124.104?F3000.

……

N0197?X-222.18?Y-28.Z337.65?A-41.026?B126.27?NO198?Z800.0?F20000.?N0199?M05?M09?N0200?M30

7) editor's numerical control program

Because cutting may appear in the cutter path that calculates in the described step 5), owe to cut or cutter interference, VERICUT(nc machining simulation software in the described step 6) of process) after software carries out machining simulation, find out and occurred cutting, owe to cut or the statement of cutter interference, if problem or program statement are more, complicated, then need readjust, calculation procedure, when problem when less or simple, method is finely tuned by hand, owing to adjust A, the B axle is bigger to the influence of adjustment amount, only adjust X during general manual setting, Y, the numerical value of three linear axes of Z, usually adjustment amount is not more than 1mm, jumps to step 6) after adjustment is finished; For example, in the withdrawing process that SI calculates, the withdrawing track is to cross earlier to blade root switching R position, again along the blade surface withdrawing, this has just caused in the withdrawing process serious mistake to cut, and the serious offense amount of cutting reaches more than the 1.5mm, and this moment is in the time of can adopting cutter to move to two blade middle parts, program is changed into along cutter direction vector straight line withdrawing, just can avoid part to cross and cut;

8) processing parts

Select the five-shaft numerical control machining center for use, by given technology file clamping parts, modeling and processing convention according to the axial-flow type integral wheel, X axle and Z axle machining coordinate initial point are located at zero centre of gyration, Y axle machining coordinate initial point is located on the long-pending folded axle of blade, processes by technical papers and machining center operating instruction.

The present invention adopts five-axle linkage to become axle and inserts the mode of milling, by selecting suitable plug in milling cutter and machined parameters, having improved integral wheel slightly slots and removes big surplus working (machining) efficiency and qualification rate, reduced the holding time of processing cost and five machining centers, solved the free form surface fixed axis insert mill after, the remaining surplus of its blade surface is inhomogeneous, needs to adopt ball cutter to carry out the processing difficult problem that polishing is handled.

The present invention is mainly used in complex free curved surface structure classes such as axial-flow type integral wheel, whole leaf joint and need removes the five-shaft numerical control of big surplus part and mill processing, and the multi-axis numerical control that also can be applicable to simple free form surface structure class part such as centrifugal integral wheel, Mould Machining mills processing.

Claims (1)

1. an integral wheel blade-section five-axle linkage change axle is inserted and is milled numerical-control processing method, it is characterized in that: carry out according to the following steps:

1) the space free curved surface is split into a plurality of zones to be processed (2)

In each zone to be processed (2), guarantee on cutter (4) cutting direction between cutting starting point and the terminating point curvature direction consistent as far as possible, cutter (4) is in processing and cross that the curvature variation is not more than 10 % on the direction;

2) stressing conditions in analysis cutter (1) process

Because it is less to the tolerance degree of radial load to plug in milling cutter, therefore, must will insert the stress of the every bit of milling cutter in the five-axle linkage process analyzes clear, to guarantee the inserting radial load minimum that milling cutter is born in the process, also to consider the durability of inserting milling cutter tool fillet R position simultaneously;

3) select suitable plug in milling cutter

According to step 1), 2) analysis, be to guarantee working (machining) efficiency, inserting milling cutter (4) diameter should not be too little, to consider simultaneously avoid cutting and the withdrawing process in the collision of knife bar and part grind, therefore, stronger appearance bits ability must be arranged, as far as possible the choice criteria cutter between blade; In addition, according to the plug in milling cutter cutting edge characteristics at center only, the side of cutter (4) cutting movement direction needs fluting in advance, does not have interference to guarantee the non-cutting of cutter (4) position;

4) planning processing route

According to the processing characteristic of plugging in milling cutter, cutter path (6) step direction cutting depth should mode from deep to shallow be processed, curved surface advances in the step direction upper edge, cutting width can change, in order to guarantee that non-cutting position and part bump, the cutting step pitch should be not more than 50 % of Tool in Cutting tread degree;

5) generate NC cutting tool track (6)

Utilize the multiaxis programing function of UG three-dimensional CAD design software and MAX-PAC turbo wheel digital control processing programming software bag, in selected cutting zone, set up and generate cutter path (6);

6) numerical control program emulation

Whether the cutter path (6) that generates is carried out the emulation of cutter path (6) through the VERICUT numerical control machining simulation system, and check to exist in emulation and cut, owe to cut or cutter interference; Cut, owe to cut or cutter interference if having, execution in step 7); Do not cut, owe to cut or cutter interference if having, skips steps 7), direct execution in step 8);

7) editor's numerical control program

Find out and occurred cutting, owe to cut or the statement of cutter interference; If problem or program statement are more, complicated, then readjust, calculation procedure, if problem is less or when simple, method is finely tuned by hand, because adjust A, the B axle is bigger to the influence of adjustment amount, only adjust the numerical value of X, Y, three linear axes of Z during general manual setting, adjustment amount is not more than 1mm usually, adjusts and jumps to step 6) after finishing;

8) processing parts.

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