Virtual Five-Axis Flank Milling of Jet Engine Impellers—Part I: Mechanics of Five-Axis Flank Milling
Virtual Five-Axis Flank Milling of Jet Engine Impellers—Part I: Mechanics of Five-Axis Flank Milling
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DOI：
10.1115/1.2815761
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发表时间：
2008-02
影响因子：
4
通讯作者：
W. Ferry;Y. Altintas
中科院分区：
文献类型：
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作者：
W. Ferry;Y. Altintas
这项工作是第一个两部分文件的切削力预测和进给优化的五轴侧铣喷气发动机叶轮。在第一部分中，提出了一个预测切削力的数学模型，用于五轴加工的锥形，螺旋，球头米尔斯与变螺距和锯齿形槽。刀具在轴向上被分成多个微分元件，由于五轴运动，每个微分元件都有自己的进给坐标系。在每个元件处，由于平移和角运动而产生的总速度被分成水平和垂直进给分量，这些分量用于计算沿着切削刃的总切屑厚度。通过将摩擦角、剪切应力和剪切角从正交切削数据库转换到斜切削平面来计算每个元素的切削力。分布的切削载荷以数字方式求和，以获得作用在刀具和刀片上的总力。该模型可用于一般的五轴侧铣加工，并支持多种刀具。预测的切削力被证明是在合理的协议与那些收集在一个原型整体叶片转子粗加工操作。
This work is the first of a two part paper on cutting force prediction and feed optimization for the five-axis flank milling of jet engine impellers. In Part I, a mathematical model for predicting cutting forces is presented for five-axis machining with tapered, helical, ball-end mills with variable pitch and serrated flutes. The cutter is divided axially into a number of differential elements, each with its own feed-coordinate system due to five-axis motion. At each element, the total velocity due to translation and angular motion is split into horizontal and vertical feed components, which are used to calculate total chip thickness along the cutting edge. The cutting forces for each element are calculated by transforming friction angle, shear stress, and shear angle from an orthogonal cutting database to the oblique cutting plane. The distributed cutting load is digitally summed to obtain the total forces acting on the cutter and blade. The model can be used for general five-axis flank milling processes, and supports a variety of cutting tools. Predicted cutting forces are shown to be in reasonable agreement with those collected during a roughing operation on a prototype integrally bladed rotor.