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首页> 外文期刊>International Journal of Computer Integrated Manufacturing >Cutting force integration at the CAM stage in the high-speed milling of complex surfaces
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Cutting force integration at the CAM stage in the high-speed milling of complex surfaces

机译：复杂表面高速铣削中CAM阶段的切削力集成

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摘要

High-speed milling (HSM) technology has been rapidly absorbed by the die and mould manufacturing industry and by the aeronautical sector. The new cutting tools can withstand much higher machining conditions than 10 years ago. Last-generation, highspeed machining centres are equipped with high-frequency spindles with hybrid ball bearings, leading to rotational speeds over 18 000r/min. Multiaxis machining can be effectively carried out in five-axis machining centres of different architecture. These new and advanced machining processes are much more complex and provide the final component with a higher added value. However, the reliability of the whole process must be reconsidered, since collisions, tool breakage and dynamic problems can result in expensive machine repairs and some parts may be impossible to recover. In order both to minimize the above problems and increase machining performance, a new machining approach based on two ideas has been developed. First, virtual verification of the NC programs, avoiding collisions or tool-machine interferences that may arise during the machining of complex surfaces. Second, toolpath optimization in the machining of complex surfaces. For this purpose a utility to estimate the cutting forces before machining has been integrated in the computer-aided manufacturing (CAM) planning process stage. The estimation of cutting force uses a semi-empirical approach, in which the pair tool/ material is characterized by six specific cutting force coefficients. The force model introduces the effect of part slope in calculations, just with tool geometry, cutting conditions, and material. The value of cutting force is used as an estimator for selecting the best cutting toolpaths for a complex surface. In this way a more accurate, better-finished surface is machined, and a reduced tool wear is withstood. The global CAM process is applied to three examples that are discussed. They are representative of a highly efficient high-speed process, without any risks of tool collisions, surface machined errors and low cutting forces.
机译：高速铣削（HSM）技术已被模具制造业和航空业迅速吸收。新的切削刀具可以承受比10年前更高的加工条件。上一代的高速加工中心配备了带有混合滚珠轴承的高频主轴，转速超过18 000r / min。可以在不同架构的五轴加工中心中有效地执行多轴加工。这些新的和先进的加工工艺要复杂得多，并为最终零件提供更高的附加值。但是，必须重新考虑整个过程的可靠性，因为碰撞，工具损坏和动态问题会导致昂贵的机器维修，并且某些零件可能无法修复。为了最小化上述问题并提高加工性能，已经开发了基于两种思想的新加工方法。首先，对NC程序进行虚拟验证，避免在复杂表面加工过程中可能发生的碰撞或工具-机器干扰。第二，复杂表面加工中的刀具路径优化。为此，在计算机辅助制造（CAM）规划过程阶段已集成了一种在加工之前估算切削力的实用程序。切削力的估计使用半经验方法，其中刀具/材料对的特征在于六个特定的切削力系数。力模型仅在刀具几何形状，切削条件和材料方面就引入了零件坡度的影响。切削力的值用作估算器，用于为复杂表面选择最佳切削路径。通过这种方式，可以加工出更精确，加工效果更好的表面，并且可以减少刀具磨损。全局CAM过程应用于所讨论的三个示例。它们代表了高效的高速过程，没有任何工具碰撞，表面机加工错误和低切削力的风险。

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