复杂曲面加工过程的广义包络理论研究

项目名称： 复杂曲面加工过程的广义包络理论研究

项目编号： No.50875012

项目类型： 面上项目

立项/批准年度： 2009

项目学科： 金属学与金属工艺

项目作者： 陈志同

作者单位： 北京航空航天大学

项目金额： 35万元

中文摘要： 广义包络理论是本项目所提出的致力于研究复杂曲面加工过程中刀具工作表面和工件设计曲面之间依一定的控制公差而构成的啮合关系及其变化规律的理论, 为提高复杂曲面的加工效率和加工精度提供必要的理论基础和基本方法体系。 本项目通过研究建立了广义包络理论的一般数学模型，提出并比较了有效特征线段的多种求解方法，证明了曲面离散方法和经纬线方法在求解误差分布函数、加工行宽等方面的有效性。建立了刀位优化、刀轨优化等问题的变分模型，为复杂曲面CAD/CAM技术的后续发展提供了一条新途径；提出了中点误差控制算法、双线驱动算法、环面刀具清根算法等重要算法，开发了应用验证软件，并将所提出的方法成功应用于航空发动机精密叶片、水轮机大型叶片的数控加工过程，显著提高了这些重要零件的加工效率和加工质量。

中文关键词： 广义包络理论；变分原理；数控加工；复杂曲面

英文摘要： Generized Envelope Principle(GEP) is a new theory to study the mesh relationship under a given tolerance between a tool's working surface(TWS) and the actual machined surface(MS) of a workpiece in the NC machining process, with which some necessary basis and methodology can be estabalished to increase the machining efficience and worpiece accuracy. In this project, a genery mathmatical model on Generized Envelope Principle(GEP) was established, a few of solution of an Effective Characteristic Curve(ECC) between the MS and TWS were proposed, in which the proposed "Workpiece-Slicing-Theory"(WST) and the "Longitude & Woof Theory"(LWT)were all proved effectice in obtaining the Distance Distribution Funnction(DDF)and machined-strip-width. Based on the variational principle, some variational equations on Cutter location optimization and toolpath optimization were proposed, which provided a new way to the future development of CAD/CAM technology on sculptured surface machining. Some important algorithm, such as aMiddle-Point-Eooro-Control algorithm, a dual-curve-driven toolpath generation algorithm and a cleaning-up machining method with torus cutter, were given and verified through simulation and experiment. A application software for the above algorithms was developed, which was successfully applied in the 5-axis NC machining of some turbine blades of aero-engine and a large scale blade of a hydro-turbine, and remarkably promoted their machining efficiency and surface quality.

英文关键词： Generized Envelope Principle(GEP); Variational principle; NC machining;Sculptured surface