复杂曲面数控铣削过程仿真与集成优化研究

发布时间：2018-04-18 12:39

本文选题：复杂曲面 + 数控铣削　；参考：《昆明理工大学》2017年硕士论文

【摘要】：随着科学技术的进步和经济水平的提高,复杂曲面零件在模具、工具、能源、交通、航空航天和海航等领域中的应用越来越广泛。目前,常见的复杂曲面类零件有雕塑曲面零件、直纹面零件、蒙皮零件以及组合曲面零件等,此类零件形状复杂、曲率变化大、空间扭曲程度高且含薄壁结构,加工难度很大,多轴数控铣削工艺方法及其加工装备成为解决复杂曲面零件加工的有效手段。其中,复杂曲面多轴数控铣削涉及到的关键技术包括复杂曲面造型、多轴铣削工艺、刀轴姿态控制、多轴数控加工刀轨计算、后置处理技术、数控加工过程仿真和铣削工艺参数优化等方面。然而,目前针对复杂曲面零件多轴数控铣削质量的研究仍缺乏面向多工艺参数、多优化目标的过程集成优化方法和手段,尚未构建能够支持CAD-CAM-CNC数据链模型的过程仿真与集成优化平台。本文以水轮机叶片为研究对象,针对其变曲率、大扭曲的型面特征及其多轴数控铣削质量难预测问题,提出了基于多轴铣削加工过程仿真与集成优化的铣削质量分析方法。首先,分析了复杂曲面多轴铣削过程中的主要工艺参数、切削行为、性能质量及其影响关系,建立了水轮机叶片的数字化模型,给出了其数控铣削工艺规划方案,在此基础上完成了刀位轨迹计算,并建立了叶片多轴铣削仿真模型;然后,搭建了叶片多轴数控铣削过程仿真集成框架,并基于OPTIMUS平台开发了多轴铣削过程系统集成接口,建立了复杂曲面多轴铣削集成数据链模型;最后,以水轮机叶片的表面铣削质量和切削力水平为优化目标,将切削速度、进给量和切削深度三个工艺参数作为输入文件完成了 455组集成仿真数据,给出了铣削过程仿真集成数据的试验设计,构建了铣削工艺参数与铣削优化目标之间的响应面模型,并得到了在论文仿真工况下叶片多轴铣削的最优工艺参数。本论文研究成果揭示了复杂曲面多轴铣削过程中工艺参数的变化规律,量化分析了不同加工工艺参数对复杂曲面铣削质量的影响,实现了加工过程中工艺信息的及时反馈和调整,缩短了仿真时间,提高了变曲率、大扭曲自由曲面铣削质量分析的准确性,对提高复杂曲面零件数控铣削质量具有十分重要的理论意义和生产应用价值。
[Abstract]:With the progress of science and technology and the improvement of economic level, complex curved surface parts are more and more widely used in the fields of mould, tool, energy, transportation, aviation and aerospace, HNA and so on.At present, the common complicated curved surface parts include sculptural curved surface parts, straight-cut surface parts, skinned parts and composite curved surface parts. The shape of this kind of parts is complex, the curvature change is large, the space distortion degree is high and contains thin-walled structure, so it is very difficult to process.Multi-axis NC milling technology and its processing equipment have become an effective means to solve the machining of complex curved surface parts.Among them, the key technologies involved in multi-axis NC milling of complex surfaces include complex surface modeling, multi-axis milling technology, cutter axis attitude control, multi-axis NC machining tool track calculation, post-processing technology.NC machining process simulation and milling process parameters optimization and so on.However, the research on multi-axis NC milling quality of complex curved surface parts is still lack of process integration optimization method and means for multi-process parameters and multi-optimization objectives.A process simulation and integration optimization platform capable of supporting CAD-CAM-CNC data link model has not yet been constructed.In this paper, taking the turbine blade as the research object, aiming at the characteristics of variable curvature, large distortion profile and difficult prediction of multi-axis NC milling quality, a milling quality analysis method based on multi-axis milling process simulation and integrated optimization is proposed.Firstly, the main technological parameters, cutting behavior, performance and quality of complex curved surface in the process of multi-axis milling are analyzed, the digital model of turbine blade is established, and the NC milling process planning scheme is given.On this basis, the tool path calculation is completed, and the simulation model of blade multi-axis milling is established. Then, the integrated framework of multi-axis NC milling process simulation is built, and the integrated interface of multi-axis milling process system is developed based on OPTIMUS platform.An integrated data link model for multi-axis milling of complex surfaces is established. Finally, the cutting speed is optimized by taking the surface milling quality and cutting force level of the turbine blade as the optimization target.Three process parameters, feed and cutting depth, are used as input files to complete 455 sets of integrated simulation data. The experimental design of milling process simulation integrated data is given, and the response surface model between milling process parameters and milling optimization target is constructed.The optimum process parameters of blade multi-axis milling are obtained under the simulation condition of the paper.The research results of this paper reveal the changing rule of process parameters in the process of multi-axis milling of complex surfaces, and quantitatively analyze the influence of different processing parameters on the milling quality of complex surfaces.The real-time feedback and adjustment of process information are realized, the simulation time is shortened, and the accuracy of milling quality analysis of variable curvature and large twisted free surface is improved.It is of great theoretical significance and practical value to improve the NC milling quality of complex curved surface parts.
【学位授予单位】：昆明理工大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG547

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