刀具半径对3D误差补偿的影响研究
Research on Influence of Tool Radius on 3D Error Compensation
摘要: 研究刀具半径对3D误差补偿的影响，提高多轴加工复杂自由曲面表面轮廓精度。首先对3D刀具误差产生机理进行分析，推导出了残留高度计算公式和误差补偿的数学模型，使用MATLAB软件分别对刀具半径与残留高度之间的关系以及补偿算法进行了仿真验证。基于五轴双摆台机床的运动学模型，结合刀具误差补偿模型，对叶片零件分别采用四种不同直径的球头铣刀进行后置处理。最后，进行了仿真和真实切削实验，并对实验结果进行了分析。刀具进行半径补偿后所加工零件，其实际加工效果与半径补偿值大小密切相关，且补偿值越小，补偿效果越明显，加工效果与理论结果越接近。8、9、9.5及10四种尺寸刀具对叶片试件进行仿真加工，与理论10刀具加工的数据对比，8、9、9.5三种尺寸刀具补偿加工后的最大残留高度值与理论刀具相比分别多0.09、0.07、0.05 mm，超差点数量与理论刀具相比多1055、462、292。刀具3D误差补偿算法，可在刀具尺寸磨损后不需要更换刀具下满足加工要求，大大提高效率，降低生产成本。刀具3D误差补偿算法的实施需在刀具磨损率较小的情况下使用，特别是精加工过程。
Abstract: This paper is proposed to study the influence of tool radius on 3D error compensation and improve the surface contour accuracy of multi-axis machining complex free-form surfaces. Firstly, the mechanism of 3D tool error generation was analyzed, and the residual height calculation formula and mathematical model of error compensation were deduced. The relationship between tool radius and residual height and the compensation algorithm were simulated and verified using MATLAB software. Based on the kinematics model of the five-axis double-swing table machine and the tool error compensation model, the blade parts are respectively post-processed with four ball-end milling cutters of different diameters. Finally, simulation and real cutting experiments were carried out, and the experimental results were analyzed. The actual machining effect of the tool after compensation is closely related to the size of the compensation value, and the smaller the compensation value, the more obvious the compensation effect, and the closer the processing effect is to the theoretical result. φ8, φ9, φ9.5, and φ10 four-size tools are used to simulate blade machining. Compared with the theoretical data of φ10 tool processing, φ8, φ9, φ9.5 three-size tools compensate the maximum residual height value after processing. The theoretical tool is 0.09, 0.07, and 0.05 mm more than the theoretical tool, and the number of excess points is 1055, 462, and 292 more than the theoretical tool. The tool 3D error compensation algorithm can meet the processing requirements without changing the tool after the tool size is worn, greatly improving the efficiency and reducing the production cost. The implementation of the tool 3D error compensation algorithm needs to be used with a small tool wear rate, especially for the finishing process.
文章引用：唐清春, 谢栋, 刘斌. 刀具半径对3D误差补偿的影响研究[J]. 机械工程与技术, 2020, 9(2): 76-88. https://doi.org/10.12677/MET.2020.92008

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