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

现代制造的目标是在航空航天生产车间进行第一次试验时，准确且最经济地生产昂贵的部件。主席的头两届任期见证了虚拟2.5轴铣削和5轴侧面铣削技术的发展，自那以后这些技术已转移到工业中。在第三个任期中，主席的研究将集中在燃气轮机叶片的5轴球头铣削技术上。在进行昂贵的资本投资之前，将建立通用的、可重构的和模块化的5轴机床运动学模型，用于叶片加工的虚拟测试。刀具路径将被平滑，以避免沿五个轴路径的轴速度不连续。根据机床的数学模型，对叶片尖曲率附近的轮廓误差进行预测和补偿。叶片沿刀具路径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5轴球头铣削叶片时的切削力、扭矩、功率、振动和尺寸形状误差。切割深度和宽度、主轴速度和进给速度将得到优化，从而实现成本最高的零件的最经济、最精确的加工。完成后，椅子将实现一个以科学为基础的模拟和优化系统，以预测机床和柔性刀片的五轴虚拟球头铣削的行为。该系统在全球航空航天、模具和模具加工行业有着广泛的应用。主席由NSERC和普惠加拿大(P&WC)公司赞助。P&WC是设计和制造小型燃气轮机发动机的世界领先者，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的国内和国际公司和研究中心的进一步支持和合作。这些发现将发表在开放文献中，该技术将通过虚拟加工软件和对研究生和实习工程师的培训向行业传播。

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.