复杂薄壁件高效高精多轴加工的几何建模与工艺优化

项目名称： 复杂薄壁件高效高精多轴加工的几何建模与工艺优化

项目编号： No.51475381

项目类型： 面上项目

立项/批准年度： 2015

项目学科： 机械、仪表工业

项目作者： 陈泽忠

作者单位： 西北工业大学

项目金额： 80万元

中文摘要： 复杂薄壁件广泛应用于国防、运输、能源等领域，其制造水平是衡量一个国家制造能力的重要标志，其高精高效加工是目前亟需解决的问题。针对以上难题，本研究从五轴加工过程的精确几何建模入手，开展复杂薄壁件高精高效工艺建模与优化研究。通过对刀具截面曲线族边界求解问题的研究，构建刀具五轴运动扫掠体的精确模型和快速求解方法。通过建立复杂薄壁件工艺刚度测量方法，并结合有限元方法与神经网络方法，实现薄壁件挠度的快速计算。构建加工过程中工件的动态几何模型，建立五轴运动中刀具工件动态啮合关系的精确模型。在上述几何模型的基础上，针对复杂薄壁件加工变形大、加工效率低问题，分别建立五轴点铣精加工路径优化模型、以及高效率四轴插铣刀具路径优化模型，结合计算智能优化求解方法，最终形成复杂薄壁件高效高精多轴数控加工工艺方法。丰富和完善了复杂薄壁件多轴数控加工理论，满足我国重大装备对复杂薄壁件多轴加工技术的需求。

中文关键词： 薄壁件；几何模型；工艺优化；切削深度

英文摘要： Complex thin-walled parts are widely used in defense, energy and transportation industry, manufacturing level of which is the crucial index of judging the manufacturing capability of a nation. It is highly demanded to develop techniques of fabricating this kind of part with high accuracy and efficiency. Aim at issues hereinbefore, Starting from modeling geometry concerning process of five-axis machining, this research conduct the study of process modeling and optimization of machining complex thin-walled parts with high accuracy and efficiency. A precise model of swept volume formed by five-axis motion of cutters is set up on the base of the study to solving the boundary of curve family formed by intersecting moving cutter with parallel planes. A device is designed and fabricated to measure the deflection of thin-walled parts, meanwhile a FEM model is established and adjusted according measured and predicted deflection. Then a neural network system is trained to represent the deflection caused by cutting forces. After the dynamic geometric model of workpiece is established, the model of calculating engagement between workpiece and cutter is set up. Based on the geometric models established above, addressing the deflection over tolerance and lower cutting efficient, a optimal model of tool path for five-axis finishing milling and a optimal model of tool path for four-axis rough plunging are established respectively. By employing computing intelligent methods, multi-axis machining process of complex thin-walled parts with high accuracy and efficiency is achieved eventually. The research achievement could enrich and improve the CNC machining theory of complex thin-walled parts and further satisfy the needs of national major equipments.

英文关键词： thin-walled parts;geometry modeling;process optimization;cutting depth