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

研究涉及一种新的加工概念，利用六轴控制。6-轴控制意味着切削工具允许用于定位的三个旋转运动以及三个平移运动。六轴联动加工中心除了具有传统的五轴联动结构外，还具有可实现刀具定位的主轴。非旋转切削刀具安装在主轴上进行6轴控制加工，允许各种加工可能性。本文研究了一种非旋转刀具角部成形的软件系统的开发。倒角加工是六轴联动加工的典型实例之一。由传统旋转工具形成的角部形状具有圆形，其不可能在没有手动精加工的情况下去除。因此，开发了一种非旋转切割工具来去除剩余部分。该刀具不仅可以用侧刃加工角部的雕塑曲面，而且可以用顶刃加工角部的尖锐曲线。通过使非旋转切削刀具沿着曲线进给，同时保持切削刃与雕刻表面相切，可以获得没有倒圆的尖锐曲线。通过一个角部成形的实验结果表明，该系统对获得无圆角的复杂曲面工件是有效的。该方法进一步扩展到加工由平面和雕刻表面组成的铣削。一种非旋转切削刀具，其沿着进给，该进给具有在雕刻表面和给定平面之间的横截面曲线。生成的CL数据被转换为实际的6轴控制NC数据。实验结果也证明了所开发的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.