First, introduction

The complex curved surface five axes linkages numerical control processing technology is now in the manufacturing industry high-tech, it is involves to the computer three dimensional modelling, the CAM automatic programming technology, the survey technology, the manufacture technology, the cutting simulation technology and so on the multi-disciplinary overlapping comprehensive technology, therefore has the higher technical difficulty. But because five axes linkages processing technology has the high accuracy, the high efficiency, the processing compatibility are strong and so on the characteristic, also enables it to adapt the complex curved surface numerical control processing well. Now, five axes linkages processing technology already in the generating set manufacturing industry, the airplane manufacturing industry, the steamboat manufacturing industry obtained the widespread application.

Programs regarding the complex curved surface five axes linkages numerical control said, because curved surface complex, also mostly for the sculpture curved surface which cannot be launched, when programming is easy to produce is not easy to realize has cut and so on the interference. And, in five axes linkages numerical control engine bed processing, NC 铣头 revolves or the work piece revolves very easy to occur interferes and collides the phenomenon, creates the work piece, the cutting tool even engine bed damage. Therefore, in actual processing, even if very experienced engineer also needs to carry on tries to cut, carries on the repeatedly debugging to the procedure, has created the manpower, the time, the energy and the material waste, also the efficiency is low.

Hypothesized manufacture system VMS (VirtualManufacturing System) is the actual manufacture system needlessly is consuming the energy and in the resources information world complete mapping. The hypothesized manufacture is takes the lead in on century 80's by US to propose, is to the real product manufacture dynamic simulation, is one kind carries in the computer but does not consume the physical resources the simulation manufacture software technology.

The hypothesized manufacture engine bed system is the reality manufacture engine bed system in the hypothesized spatial mapping, it is the hypothesized system which is composed by the hypothesized engine bed -> cutting tool -> jig -> work piece, has the realistic engine bed processing system complete function, the characteristic and the behavior, can complete the realistic engine bed processing system similar hypothesized production task. Carries on the simulation through the hypothesized manufacture engine bed to the complex curved surface five axes linkages numerical control processing, can really reflect in the manufacture processing process has cut, interference and so on the collision, has provided the data for the procedure revision; Can carry on to the processing procedure repeatedly debugs, in does not consume the material, the energy, does not take the engine bed time in the situation to obtain the correct numerical control processing procedure. The hypothesized manufacture engine bed system can provide in the processing process the essential data, after like the optimized cutting parameter, the always process period and so on, may appraise the processing strategy through them the fit and unfit quality and the improvement processing plan; Can further carry on the optimization to the processing procedure, reduces in the machining process the spatial travelling schedule 走刀 time and the adjustment complex curved surface different position processing for rate.

Second, hypothesized manufacture engine bed system

Below in view of the complex curved surface five axes interlock system processing existence question, the utilization commercial software establishment hypothesized manufacture engine bed system, needs to carry on the engineering research.

1. hypothesized manufactures engine beds constitution

The hypothesized manufacture engine bed must be able completely really to respond the realistic engine bed, regardless of is in the engine bed topology, the outlook size, or the movement function aspect all consistent or is similar with the realistic engine bed. The hypothesized manufacture engine bed establishment mainly includes the engine bed geometry structure, the control system and the cutting tool storehouse establishment. The hypothesized engine bed must be able really to respond the realistic engine bed, first requests to have the same engine bed topology, next engine bed each 运动�?geometry size request with realistic engine bed consistent, specially five axes linkages engine bed has two rotation axes NC 铣头 and the Z axis slippery pillow size needs with the realistic engine bed completely consistent, moreover, the engine bed each 运动�?movement limit and the relative relations also must be consistent with the realistic engine bed. The control system establishment goal is causes the hypothesized control system to have with the realistic system same function, and can to the engine bed function, like function code and so on G code, M code carry on the definition, and realization to hypothesized engine bed control function. The establishment engine bed cutting tool storehouse mainly is the establishment uses in actually to make in the system same size specification each kind of cutting tool, by real simulation cutting process.

2. engine beds simulations and verification

Increases the work piece semifinished materials, the cutting tool and the jig on the hypothesized manufacture engine bed, the establishment programming coordinate system and the engine bed coordinate system relative position relations, after the increase processing procedure, was allowed to realize the simulation which processed to the realistic engine bed. The simulation can really simulate has cut, the collision and so on each kind of phenomenon, is concurrent the warning, marks has this phenomenon position.

3. program optimizations

The program optimization first needs to aim at the different product material and the cutting tool material establishment individuality program optimization storehouse, this optimized storehouse needs through to make the massive cuttings to experiment establishes. When program optimization acts according to the different processing material and the cutting tool, in the choice optimization storehouse example carries on the optimization to the procedure. After the optimization, in the complex curved surface different processing region automatic setup different cutting for rate, maintains each tooth cutting quantity and metal removeing rate constant, thus enhancement processing efficiency.

Third, hypothesized manufacture in complex curved surface processing application example

The hydraulic turbine leaf blade's processing belongs to the large-scale complex sculpture curved surface the processing, its semifinished materials volume big, the material price is expensive, uses the hypothesized manufacture technology to carry on the processing simulation to the processing process, can very good dodge in each kind of manufacture the risk, improves the components processing quality and the processing efficiency. Adds water the turbine leaf blade with the hypothesized manufacture technology to carry on the engine bed simulation flow like chart 1 to show.

Chart 1 hydraulic turbine leaf blade processing simulation flow schematic drawing

We apply VERICUT engine bed simulation software, establishes the hypothesized manufacture engine bed through it on the computer, can realize adds water the turbine leaf blade processing process engine bed simulation, the program check as well as the program optimization. Under take some interflow type hydraulic turbine leaf blade's engine bed simulation as the example introduced utilizes the VERICUT software realization complex curved surface hypothesized machine tool construction the method.

1.FKSA1800 engine bed model system establishment

FKSA1800 is a some hydraulic turbine factory single arm five axes linkages milling machine, has X, Y, the Z three straight reels and B, the C two rotation axes. The Y axis attaches to the Z axis, the rotation axis C axis attaches to the Z axis, the rotation axis B axis attaches to the C axis, belongs to the Head-Head five axes linkages engine bed. The work table size is 1.6m×4m, X, Y, the Z axis travelling schedule respectively is 3m, 2m, 1m, the C axis travelling schedule 0° ~ + 360°, B axis travelling schedule -105° ~ + 105°.

Software first establishes the engine bed through V E R I C U T the topology, then increases the engine bed as well as each 运动�?three dimensional geometry entity. Regarding shape complex geometry entity, if two axes N the C mill is prime, passable C A D software has composed the full-scale mockup, again reads in VERICUT through the data connection, and according to correct position relations assembly. The FKSA1800 control system is the SIEMENS840D system, VERICUT has the many kinds of control system template storehouse, may choose the suitable control system, and according to the need, the programming language which brings using VERICUT, increases the suitable G code and the M code function. The processing leaf blade's cutting tool for phi the 100R10 surface milling cutter, phi 63 end mills, phi 6 drills prime, defines these in VERICUT to need the cutting tool. The FKSA1800 hypothesized engine bed model like chart establishes which using VERICUT software 2 shows.

Chart 2 FKSA1800 hypothesized engine bed model

2. Complex curved surface five axes linkages processing engine bed simulation, verification as well as program optimization

When V E R I C U T simulation, calls in the FKSA1800 engine bed, the increase semifinished materials, the jig, the increase processing procedure as well as needs the cutting tool to be allowed to carry on the processing simulation. Through the engine bed simulation can really reflect the water leakage turbine leaf blade actual processing situation, can inspect has cut, phenomenon and so on collision, can calculate the processing to need the time, and can after the software analysis functional check simulation processing the hydraulic turbine leaf blade's size precision, after also may call in the design model same simulation processing the model to carry on the comparison, to uses the different processing plan and the processing strategy procedure carries on the simulation. According to processes the data which the simulation obtains to be allowed to distinguish the processing plan and the processing strategy fit and unfit quality, are advantageous to engineer to process the plan the selection. Through the simulation can discover before in the procedure exists the question, and occurs in the actual processing carries on the revision, greatly enhanced the programming efficiency, saved the cost. Carries on the program optimization using VERICUT, needs beforehand to experience according to the former processing and to process the experimental establishment suits the hydraulic turbine leaf blade processing the program optimization example storehouse, when the simulation chooses the appropriate procedure processing optimization example (basis cutting tool diameter, material, components material and so on) to the procedure carries on the optimization, change procedure different position entering for rate maintains each tooth cutting quantity and metal removeing rate constant. To optimizes after the procedure to be allowed again to carry on the cutting simulation to examine it whether satisfying, thought is inappropriate may the appropriate readjustment parameter again optimize, until satisfaction. Carries on the cutting simulation and the engine bed with the VERICUT hydraulic turbine leaf blade imitates the eternal truth chart 3 to show.

Chart 3 hydraulic turbine leaf blade cutting simulation and engine bed simulation

Fourth, concluding remark

Utilizes the hypothesized manufacture technology to carry on the simulation to the complex curved surface five axes linkages numerical control processing, can solve very many problems which exists in the numerical control programming and the reality manufacture, has solved to the manpower, the time, the resources waste question, and enhanced the processing efficiency, reduced the manufacture cycle, played the good role in the practical application.