Integrated Planning for Precision Machining of Complex Surfaces

9500020 Menq本研究的目标是开发复杂曲面几何形状精密加工的综合框架，其中产品质量和生产率在工艺开发阶段而不是生产周期的制造阶段进行计划和控制。在三维曲面零件的制造中，端面铣削是应用最广泛的加工工艺之一。将建立可靠的数学过程模型来确定端面铣削的最佳加工条件。第一个任务将是开发各种端面铣削过程中切削力和由此产生的表面误差的预测模型。第二个任务是开发先进的加工策略和补偿方案，利用开发的预测能力来规划最优的切割路径和进给速度，以减少生产时间和成本，并通过在实际加工表面之前修正预期误差来提高产品质量。美国大约有五万家小型机械厂可以从这项研究中受益。研究目的在于加深对端面铣削加工过程中的加工性能和尺寸误差形成的认识，并为复杂曲面的精密加工提供一个完整的框架。所开发的模型可以在开放式的计算机辅助设计与制造系统中实现，从而建立三维复杂曲面加工的智能加工规划系统。

9500020 Menq The goal of this research is to develop an integrated framework for precision machining of complex surface geometries, in which product quality and productivity are planned and controlled in the process development phase rather than in the manufacturing phase of the production cycle. The present study focuses on end milling, one of the most widely used machining processes in the manufacture of parts with three-dimensional sculpted surfaces. Reliable mathematical process models will be developed to determine the optimum machining conditions in end milling. The first task will be to develop predictive models for cutting forces and the resulting surface errors in various end milling processes. The second task is to develop advanced machining strategies and compensation schemes that utilize the developed predictive capability to plan optimal cutting paths and feedrates for the reduction of production time and costs, and to improve product quality by correcting the anticipated errors before actually machining a surface. There are about fifty thousand small machine shops in the United States that could gain some benefit from this research. The research is intended to enhance the understanding of the cutting performance and dimensional error formation in the end milling process, and to develop an integrated framework for precision machining of complex surface geometries. The models developed here can be implemented in an open computer-aided design and manufacturing system to establish an intelligent machining planning system for three-dimensional sculptured surface machining.