难加工材料数控铣削刀具磨损建模、仿真与误差补偿研究

项目名称： 难加工材料数控铣削刀具磨损建模、仿真与误差补偿研究

项目编号： No.50805078

项目类型： 青年科学基金项目

立项/批准年度： 2009

项目学科： 电工技术

项目作者： 张臣

作者单位： 南京航空航天大学

项目金额： 22万元

中文摘要： 本课题以难加工材料数控铣削刀具为研究对象，采用理论分析与实验研究相结合的思路，分析刀具磨损和工艺参数等刀具磨损影响因素的关系，建立各因素与刀具磨损的对应指数关系组合模型，以复映方式将加工实验刀具磨损量映射到对刀具加工几乎无磨损产生的较软的易加工材料上，运用数学处理和实验测量确定刀具磨损模型中各个系数；然后基于建立的刀具磨损模型，设计仿真算法，对数控铣削加工刀具磨损进行仿真预测，离线提前或在线实时预报刀具磨损状态，实现刀具磨损状态监测的目的；同时建立考虑刀具磨损引起的加工误差仿真模型，预测数控铣削过程由刀具磨损产生的误差，并设计高效误差补偿刀具磨损的最佳方案，实现保证数控铣削加工质量和延长刀具使用寿命的目的。本项目的方法具有刀具磨损测量设置简单、复映测量方式灵活、不需机床停机、方便实现刀具磨损状态监测、提前预报和补偿误差的优势，在产品质量检测、虚拟制造、高效数控加工等领域具有广泛应用前景。

中文关键词： 数控铣削加工；刀具磨损；复映测量；物理仿真；误差补偿

英文摘要： The project analyzes relationship between tool wear and cutting process parameter factors using the combination ideas of theoretical analysis and experimental study for difficult-cut-materials NC milling cutter and establishes model of various factors and the corresponding index relationship. Tool wear are reflected by mapping measurements mode in machining experiments and Tool wear model coefficients are decided using math process and experiments measurements. And then tool wear status is predicted off-line in advance or on-line real-time to realize the purpose of tool wear status inspection by designing simulation algorithm based on the established tool wear model. At the same time machining error simulation model is proposed considering wear-induced error to predict machining error in the NC milling process, and the efficient error compensation method is proposed to realize the purpose of ensure of NC milling quality and extend tool life. The proposed method has advantages of simple setup in tool wear measurements, a flexible mapping measure way, convenient realization of tool wear status inspection without downtime for machining tools, prediction and compensation machining error in advance and has broad application prospects in product quality inspection, virtual manufacturing and high-performance NC machining.

英文关键词： NC machining;Tool wear;Mapping measurement;Physical simulation; Error compensation