Edged Corner Shaping and Pocket Milling by Means of 6-Axis Control Machining

研究了一种利用六轴联动控制的加工新概念。6轴控制意味着刀具允许三个旋转运动进行定位，以及三个平移运动。六轴联动加工中心除传统的五联动控制结构外，还配备了可实现刀具定向的主轴。非回转刀具安装在主轴上进行六轴联动控制加工，允许多种加工可能性。研究开发了一种非回转刀具转角成形软件系统。转角成形是六轴联动加工的典型例子之一。传统回转工具成型的拐角形状有一个圆形，如果不进行手工精加工，是不可能去除的。因此，开发了一种非旋转刀具来去除剩余的刀具。该刀具不仅可以加工具有侧切削刃的拐角的雕刻面，而且可以与顶切削刃形成拐角的尖锐曲线。通过沿曲线进给非旋转刀具，同时保持刀具刃口与雕刻面相切，可以得到一条不带圆的尖锐曲线。拐角成形实验结果表明，该系统对加工无圆角的复杂曲面零件是有效的。该方法被进一步扩展到加工由平面和雕刻曲面组成的口袋铣削。一个非旋转的刀具沿着一条在雕刻面和给定平面之间的横截面曲线进给。将生成的CL数据转换为实际的6轴控制NC数据。实验结果也验证了所开发的计算机辅助设计软件的有效性。

The study deals with a new machining concept by making use of 6-axis control. 6-axis control implies that a cutting tool allows three rotational movements for positioning as well as three translational ones. A 6-axis control machining center is equipped with a main spindle cpable of tool orientation in addition to conventional 5-axis control sturcture. Non-rotational cutting tool is mounted at the main spindle to carry out the 6-axis control machining, which allows a variety of machining possibilities. The study deals with the development of a software system for corner shaping by use of a non-rotational cutting tool. Conrner shaping is one of typical examples of 6-axis control machining. The corner shape formed by conventional rotational tools has a round, which is impossible to remove without manual finishing. Thus, a non-rotational cutting tool was developed to remove the remaining. The tool can not only finish a sculptured surface of a corner with the side cutting edge, but also form a sharp curved line of a corner with the top cutting edge. A sharp curved line without a round is obtained by feeding the non-rotational cutting tool along the curved line, while keeping the cutting edge tangent to the sculptured surface. From an experimental result of corner shaping, it is found that the system is valid to obtain workpieces consisting of sculptured surfaces without round conrner. The method is further expanded to machine a pocket milling consisting of planes and sculptured surfaces. A non-rotational cutting tool is fed along with a cross-sectional curved line between sculptured surface and a given plane. A generated CL data are transformed to the actual 6-axis control NC data. The validity of CAM software developed in the study is also found from experimental results.