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的第一次试验中准确和最经济地生产昂贵的零件。在主席的前两个任期内，开发了虚拟2 ½轴侧铣和5轴侧铣技术，这些技术已被转移到工业领域。在第三个任期内，主席的研究将集中在五轴球头铣削燃气涡轮机叶片所使用的技术。一个通用的，可重构的和模块化的五轴机床运动模型将建模为虚拟测试叶片加工之前，昂贵的资本投资。刀具路径将被平滑以避免沿沿着五轴路径的轴速度的不连续性。根据机床的数学模型，预测并补偿叶片尖曲率附近的轮廓误差。将对叶片沿着刀具路径的时变结构动力学进行建模，并将其集成到虚拟加工系统中，以预测叶片5轴球头铣削过程中的切削力、扭矩、功率、振动和尺寸形状误差。切削深度和宽度、主轴速度和进给速度将得到优化，从而实现对昂贵零件的最经济、最精确的加工。完成后，主席将建立一个基于科学的模拟和优化系统，以预测机床的行为和柔性叶片的五轴虚拟球头铣削。该系统在航空航天、模具加工等领域有着广泛的应用。P&WC在小型燃气涡轮机发动机的设计和制造方面处于世界领先地位，并拥有大量复杂的3至5轴加工应用。这项研究得到了世界各地主要国家和国际公司以及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和研究生和实践工程师的培训传播到工业界。

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.