NSERC/P&WC Industrial Research Chair in Virtual High Performance Machining

现代制造业的目标是在航空航天生产车间第一次试制时精确和最经济地生产昂贵的零件。在主席的前两届任期内，开发了虚拟的2½轴铣削和5轴侧面铣削技术，这些技术已转移到工业中。在第三学期，主席的研究将集中在燃气轮机叶片的五轴球端铣削技术上。一个广义的、可重构的、模块化的五轴机床运动学模型将被建模，用于在昂贵的资本投资之前进行叶片加工的虚拟测试。刀具路径将被平滑，以避免沿五轴路径轴速度的不连续。基于机床的数学模型，对叶片尖锐曲率周围的轮廓误差进行预测和补偿。叶片沿刀具轨迹的时变结构动力学将被建模，并集成到虚拟加工系统中，以预测叶片五轴球端铣削过程中的切削力、扭矩、功率、振动和尺寸形状误差。切割的深度和宽度、主轴速度和进给速度将得到优化，从而对昂贵零件进行最经济、最精确的加工。完成后，Chair将实现基于科学的仿真和优化系统，以预测机床和柔性刀片的五轴虚拟球端铣削的行为。该系统在世界范围内的航空航天、模具加工等行业有着广泛的应用。主席由NSERC和加拿大普惠公司（P&WC）赞助。P&WC是小型燃气涡轮发动机设计和制造的全球领导者，拥有大量复杂的3至5轴加工应用。这项研究得到了来自世界各地的主要国家和国际公司和研究中心的额外支持和合作。研究结果将发表在公开文献中，该技术将通过虚拟加工软件以及研究生和实践工程师的培训传播到工业中。

The objective of modern manufacturing is to produce costly parts accurately and most economically at first trialon aerospace production floors. The first two terms of the Chair saw the development of the virtual 2 ½- axismilling and 5-axis flank milling technologies, which have since been transferred to industry. In the third term,the Chair's research will focus on the technologies used in 5-axis ball end milling of gas turbine blades.A generalized, reconfigurable and modular kinematic model of 5-axis machine tools will be modeled forvirtual testing of blade machining ahead of costly capital investments. The tool paths will be smoothed to avoiddiscontinuities in the axis velocities along five axis paths. The contouring errors around the sharp curvatures ofblades will be predicted and compensated based on the mathematical model of the machine tool. The timevarying structural dynamics of the blade along the tool path will be modeled, and integrated into the VirtualMachining System to predict cutting forces, torque, power, vibrations and dimensional form errors during5-axis ball-end milling of blades. The depth and width of cuts, spindle speeds and feed rates will be optimized,leading to the most economical yet accurate machining of costly parts. When completed, the Chair will achievea science-based simulation and optimization system to predict the behaviour of machine tools and the five-axisvirtual ball end milling of flexible blades. The system has a wide application in the aerospace, die and moldmachining industry worldwide.The Chair is sponsored by NSERC and Pratt & Whitney Canada (P&WC) Corporation. P&WC is a worldleader in the design and manufacturing of small gas turbine engines, and has a significant number of complex3- to 5-axis machining applications. This research draws additional support and collaboration from majornational and international companies and research centres worldwide. The findings will be published in openliterature, and the technology will be disseminated to industry through Virtual Machining Software and thetraining of graduate students and practicing engineers.