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误差控制和减少加工误差是大型叶片曲面类零件五轴联动数控加工中的重要任务之一。本文基于分析和建立加工曲面的型面几何偏差与加工刀位规划参数的关系 ,提出几何误差的控制方法。基于刀具与工件的五维包络运动分析 ,对五轴联动加工中影响较大的的非线性误差进行较为严格的计算 ,提出自适应步长方法以有效控制刀触点轨迹误差。对五轴联动加工中的残余高度误差进行较为严格的分析 ,并提出有效控制几何误差的方法和措施。文中的方法结合CAM软件进行刀位轨迹计算 ,已成功地用于大型轴流式和混流式水轮机叶片五轴联动数控加工中 ,在满足精度要求下 ,加工叶片的效率有明显的提高 ,表明提出的方法和措施能有效控制大型塑曲面加工的几何误差。
Error control and reduction of machining errors are one of the most important tasks in the five-axis CNC machining of large-blade blade surfaces. In this paper, based on the analysis and establishment of the relationship between the geometry deviation of the machined surface and the tool position planning parameters, a method of geometric error control is proposed. Based on the five-dimensional envelope motion analysis of the tool and the workpiece, a more rigorous calculation is made on the nonlinear errors that have a great influence on the five-axis machining. The adaptive step length method is proposed to effectively control the tool path error. The residual height error in the five-axis linkage machining is analyzed more rigorously and the methods and measures for controlling the geometric errors are proposed. The method in this paper is combined with CAM software to calculate tool path. It has been successfully used in five-axis NC machining of large-scale axial-flow and multi-flow turbine blades. Under the requirement of accuracy, the efficiency of processing blades is obviously improved, Methods and measures can effectively control the geometric errors of large plastic surface processing.