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

利用六轴控制提出了一种新的加工理念。六轴控制意味着刀具允许三次旋转运动来定位以及三次平移运动。六轴控制加工中心在传统的五轴控制结构的基础上，增加了一个能实现刀具定向的主轴。非旋转刀具安装在主轴上进行6轴控制加工，允许多种加工可能性。研究了一种利用非旋转刀具进行角形加工的软件系统的开发。角形加工是六轴控制加工的典型实例之一。传统的旋转工具形成的转角形状有一个圆，没有手工精加工是不可能去除的。因此，开发了一种非旋转切削工具来去除残留物。该工具不仅可以用侧切削刃完成一个角的雕刻面，还可以用上切削刃形成一个角的尖锐曲线。通过沿曲线进给非旋转刀具，同时保持切削刃与雕刻表面相切，获得无圆的锋利曲线。角形实验结果表明，该系统可以有效地得到无圆角曲面的工件。该方法进一步扩展到加工由平面和雕刻表面组成的口袋铣削。非旋转刀具沿着雕刻表面和给定平面之间的横截面曲线进给。生成的CL数据转换为实际的6轴控制NC数据。实验结果也证明了本研究开发的CAM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.