整体叶轮铣削加工弹性变形预测及误差补偿研究
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摘要
整体叶轮采用一体式结构,不仅可以减少发动机的零件数量,而且在很大程度上提高了发动机的性能,因此在航空、航天领域得到了广泛应用。整体叶轮通常是利用多轴联动数控铣削方法加工成型。由于整体叶轮的叶片多为薄壁结构,所以在数控铣削过程中易受到切削力作用发生弹性变形,进而产生加工误差。薄壁叶片加工误差控制一直以来都是实现整体叶轮精密加工的关键和难点。加工过程物理仿真技术的出现和不断发展为解决上述问题提供了有效手段,但尚有许多研究工作亟待开展。为此,本文围绕提高整体叶轮薄壁叶片加工精度问题,对整体叶轮几何造型实现、无干涉刀位轨迹生成、多轴变工况条件下铣削力预测、自由曲面薄壁叶片弹性变形量计算以及加工误差补偿方法等内容进行了深入研究和探讨。
对整体叶轮几何造型实现以及刀位轨迹生成方法进行了研究,为后续研究工作的开展奠定了基础。基于B样条技术给出了曲面延伸、曲面偏置、曲面裁剪、曲面间圆角过渡的实现算法,用于完成整体叶轮的几何造型。在此基础上,进行了半开式整体叶轮数控铣削加工工艺流程设计,给出了粗加工刀具尺寸选择、过切现象避免以及粗加工分层实现等关键问题的解决方法。建立了相邻刀触点间弦高误差计算模型,提出了一种自适应步长法完成了刀位轨迹规划工作,利用直接距离法实现了刀位干涉检查与修正,并针对双转台式五轴数控机床讨论了后置处理算法。
对整体叶轮自由曲面薄壁叶片点铣加工过程中铣削力预测方法进行了研究。提出了一种瞬时参与切削刀刃微元的判定算法,用于确定瞬时铣削力模型中积分公式上下限,完成了瞬时铣削力的预测。该判定算法涉及到两个关键问题：一是数控铣削力工过程中刀具扫描体的求解；二是工件曲面Z-map模型的建立与更新。提出了一种五轴数控铣削加工过程中刀具扫描体的求解方法：先根据包络理论在刀位点处推导出包络轮廓线方程,然后再用B样条方法对刀位轨迹上所有刀位点处的包络轮廓线进行曲面拟合,进而获得刀具扫描体曲面。利用直线与自由曲面的求交算法实现了工件曲面和刀具扫描体曲面Z-map模型的建立,将两个Z-map模型进行布尔运算完成了工件曲面Z-map模型的更新。在此基础上,根据自由曲面薄壁叶片点铣加工刀位特点,建立了一个考虑刀具倾角因素的平均铣削力经验公式,设计了多因素正交试验,进而对经验公式中的铣削力系数进行了标定,并对叶片五轴数控铣削加工过程中的铣削力预测结果进行了验证。
对整体叶轮自由曲而薄壁叶片点铣加工过程中弹性变形量计算及误差补偿方法进行了研究。考虑了铣削力与弹性变形之间的耦合效应,将切削深度,切削宽度和刀轴倾角三个切削因素作为迭代计算的反馈变量,建立了自由曲面薄壁叶片点铣加工过程中铣削力与弹性变形量之间的迭代格式,利用Matlab和Ansys软件集成实现了自由曲面薄壁叶片实例在各个刀触点处弹性变形量的计算,预测了薄壁叶片实例的弹性变形规律。在获得各刀触点处弹性变形量的基础上,对自由曲面薄壁叶片加工误差离线补偿方法进行了研究。首先给出了单次补偿情况下残余误差的计算方法,然后应用镜面补偿法对自由曲面薄壁叶片实例进行了加工误差补偿量的迭代计算。
为了验证本文方法的可行性和有效性,开展了整体叶轮加工实验、叶片测量实验以及叶片加工误差分析等工作。首先在双转台式五轴联动数控机床上完成了自由曲面叶型整体叶轮的加工实验,选定两个相邻叶片作为实验样件,一个叶片是未进行补偿情况下加工获得的,另一个叶片是应用本文提出的方法进行误差补偿后加工获得的；然后进行了整体叶轮叶片数据测量实验,并利用逆向工程软件Geomagic完成了叶片曲面的重构；最后通过对两个叶片样件曲面加工误差进行对比分析,验证了本文自由曲面薄壁叶片铣削加工弹性变形预测及误差补偿方法的正确性和有效性。
Integral impeller is widely used in the field of aerospace engineering, which is beneficial to reduction of total engine parts and improvement of engine performance. It is usually machined by using multi-axis numerical control (NC) milling method. The vanes of most integral impellers have complex surface modeling with thin-walled structure, and they may easily produce deformation caused by cutting force during machining process. Deformation error control of thin-walled vane is always a key and difficult techonolgy to realize precision machining of integral impeller. Although machining process simulation technology is an effective way to solve the above problem, a plenty of research works need to be developed. Therefore, in order to improve machining accuracy of integral impeller, integral impeller geometric modeling, tool path generating, cutting force prediction for five-axis milling process, elastic deformation calculation of thin-walled vane and machining error compensation have been studied in this paper.
Firstly, the method of integral impeller geometric modeling and tool path generating is researched to lay a foundation for the following chapters. On the basis of B-spline technique, some common methods of surface editing, such as surface extension, offsetting, trimming and fillet transition are achieved for geometric modeling of integral impeller. And then some works include design of NC milling technological process, tool path planning, tool interference checking and correction and post processing are researched.
Secondly, the method of cutting force prediction for NC milling process of free-form surface thin-walled vane is researched. An algorithm for instantaneous engaged cutting edge elements identification is proposed to ascertain upper and lower limits of the integral in a cutting force model. This identification algorithm involves two key techniques:one is the generation of the tool swept volume; the other is establishment and the update of Z-map model. Based on the envelope theory, the equation of envelope curve at each cutter location point is derived, and then tool swept volume surface for five-axis NC milling is constructed by B-spline fitting. The Z-map models of workpiece and tool swept volume are established by an intersection algorithm between line and free-form surface, and then update of the workpiece is realized by a boolean operation between workpiece Z-map model and tool swept volume Z-map model. According the cutter location characteristics of free-form surface thin-walled vane milling process, an empirical formula considered tool inclination angle of average cutting force is established, the undetermined coefficients is calibrated by carrying out an orthogonal test, and then the validity of this empirical formula is verified by using the AdvantEdge PM software.
Thirdly, the method of elastic deformation calculating and error compensation for NC milling process of free-form surface thin-walled vane is researched. Considering the coupling relationship between cutting force and elastic deformation, an iteration format for calculating elastic deformation of free-form surface thin-walled vane is presented with cutting depth, cutting width and tool inclination angle as feedback variables, and then elastic deformation at each cutter contact point of a free-form surface thin-walled vane example is calculated in accordance with this iteration format by using Matalb and Ansys software. Base on this, the error compensation of the thin-walled vane example is studied by applying mirror method.
Finally, in order to verify validation of the methods proposed in this paper, some works such as machining experiment of integral impeller, measuring experiment of vane and analysis of vane machining error are developed successively. During machining experiment of integral impeller under five-axis CNC machine with dual rotary tables, two adjacent vanes are selected as sample pieces, one is without error compensation, and the other is with error compensation proposed in this paper. Data measurement of impeller is carried out by using a3D scanner, and then surface reconstruction of the sample pieces is completed by applying Geomagic software. Comparison analysis of machining errors from two sample pieces is done, and the results indicate that the methods proposed in this paper are effective and valid.
对整体叶轮几何造型实现以及刀位轨迹生成方法进行了研究,为后续研究工作的开展奠定了基础。基于B样条技术给出了曲面延伸、曲面偏置、曲面裁剪、曲面间圆角过渡的实现算法,用于完成整体叶轮的几何造型。在此基础上,进行了半开式整体叶轮数控铣削加工工艺流程设计,给出了粗加工刀具尺寸选择、过切现象避免以及粗加工分层实现等关键问题的解决方法。建立了相邻刀触点间弦高误差计算模型,提出了一种自适应步长法完成了刀位轨迹规划工作,利用直接距离法实现了刀位干涉检查与修正,并针对双转台式五轴数控机床讨论了后置处理算法。
对整体叶轮自由曲面薄壁叶片点铣加工过程中铣削力预测方法进行了研究。提出了一种瞬时参与切削刀刃微元的判定算法,用于确定瞬时铣削力模型中积分公式上下限,完成了瞬时铣削力的预测。该判定算法涉及到两个关键问题：一是数控铣削力工过程中刀具扫描体的求解；二是工件曲面Z-map模型的建立与更新。提出了一种五轴数控铣削加工过程中刀具扫描体的求解方法：先根据包络理论在刀位点处推导出包络轮廓线方程,然后再用B样条方法对刀位轨迹上所有刀位点处的包络轮廓线进行曲面拟合,进而获得刀具扫描体曲面。利用直线与自由曲面的求交算法实现了工件曲面和刀具扫描体曲面Z-map模型的建立,将两个Z-map模型进行布尔运算完成了工件曲面Z-map模型的更新。在此基础上,根据自由曲面薄壁叶片点铣加工刀位特点,建立了一个考虑刀具倾角因素的平均铣削力经验公式,设计了多因素正交试验,进而对经验公式中的铣削力系数进行了标定,并对叶片五轴数控铣削加工过程中的铣削力预测结果进行了验证。
对整体叶轮自由曲而薄壁叶片点铣加工过程中弹性变形量计算及误差补偿方法进行了研究。考虑了铣削力与弹性变形之间的耦合效应,将切削深度,切削宽度和刀轴倾角三个切削因素作为迭代计算的反馈变量,建立了自由曲面薄壁叶片点铣加工过程中铣削力与弹性变形量之间的迭代格式,利用Matlab和Ansys软件集成实现了自由曲面薄壁叶片实例在各个刀触点处弹性变形量的计算,预测了薄壁叶片实例的弹性变形规律。在获得各刀触点处弹性变形量的基础上,对自由曲面薄壁叶片加工误差离线补偿方法进行了研究。首先给出了单次补偿情况下残余误差的计算方法,然后应用镜面补偿法对自由曲面薄壁叶片实例进行了加工误差补偿量的迭代计算。
为了验证本文方法的可行性和有效性,开展了整体叶轮加工实验、叶片测量实验以及叶片加工误差分析等工作。首先在双转台式五轴联动数控机床上完成了自由曲面叶型整体叶轮的加工实验,选定两个相邻叶片作为实验样件,一个叶片是未进行补偿情况下加工获得的,另一个叶片是应用本文提出的方法进行误差补偿后加工获得的；然后进行了整体叶轮叶片数据测量实验,并利用逆向工程软件Geomagic完成了叶片曲面的重构；最后通过对两个叶片样件曲面加工误差进行对比分析,验证了本文自由曲面薄壁叶片铣削加工弹性变形预测及误差补偿方法的正确性和有效性。
Integral impeller is widely used in the field of aerospace engineering, which is beneficial to reduction of total engine parts and improvement of engine performance. It is usually machined by using multi-axis numerical control (NC) milling method. The vanes of most integral impellers have complex surface modeling with thin-walled structure, and they may easily produce deformation caused by cutting force during machining process. Deformation error control of thin-walled vane is always a key and difficult techonolgy to realize precision machining of integral impeller. Although machining process simulation technology is an effective way to solve the above problem, a plenty of research works need to be developed. Therefore, in order to improve machining accuracy of integral impeller, integral impeller geometric modeling, tool path generating, cutting force prediction for five-axis milling process, elastic deformation calculation of thin-walled vane and machining error compensation have been studied in this paper.
Firstly, the method of integral impeller geometric modeling and tool path generating is researched to lay a foundation for the following chapters. On the basis of B-spline technique, some common methods of surface editing, such as surface extension, offsetting, trimming and fillet transition are achieved for geometric modeling of integral impeller. And then some works include design of NC milling technological process, tool path planning, tool interference checking and correction and post processing are researched.
Secondly, the method of cutting force prediction for NC milling process of free-form surface thin-walled vane is researched. An algorithm for instantaneous engaged cutting edge elements identification is proposed to ascertain upper and lower limits of the integral in a cutting force model. This identification algorithm involves two key techniques:one is the generation of the tool swept volume; the other is establishment and the update of Z-map model. Based on the envelope theory, the equation of envelope curve at each cutter location point is derived, and then tool swept volume surface for five-axis NC milling is constructed by B-spline fitting. The Z-map models of workpiece and tool swept volume are established by an intersection algorithm between line and free-form surface, and then update of the workpiece is realized by a boolean operation between workpiece Z-map model and tool swept volume Z-map model. According the cutter location characteristics of free-form surface thin-walled vane milling process, an empirical formula considered tool inclination angle of average cutting force is established, the undetermined coefficients is calibrated by carrying out an orthogonal test, and then the validity of this empirical formula is verified by using the AdvantEdge PM software.
Thirdly, the method of elastic deformation calculating and error compensation for NC milling process of free-form surface thin-walled vane is researched. Considering the coupling relationship between cutting force and elastic deformation, an iteration format for calculating elastic deformation of free-form surface thin-walled vane is presented with cutting depth, cutting width and tool inclination angle as feedback variables, and then elastic deformation at each cutter contact point of a free-form surface thin-walled vane example is calculated in accordance with this iteration format by using Matalb and Ansys software. Base on this, the error compensation of the thin-walled vane example is studied by applying mirror method.
Finally, in order to verify validation of the methods proposed in this paper, some works such as machining experiment of integral impeller, measuring experiment of vane and analysis of vane machining error are developed successively. During machining experiment of integral impeller under five-axis CNC machine with dual rotary tables, two adjacent vanes are selected as sample pieces, one is without error compensation, and the other is with error compensation proposed in this paper. Data measurement of impeller is carried out by using a3D scanner, and then surface reconstruction of the sample pieces is completed by applying Geomagic software. Comparison analysis of machining errors from two sample pieces is done, and the results indicate that the methods proposed in this paper are effective and valid.
引文
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