Research On Five-Axis Post-processing Technology For Integral Impeller

Integral impellers, which are mainly manufactured using five-axis NC machine tools, arewidely used in aerospace, aircraft and automobile industry. Because of the additional tworotating components, five-axis machining are faced with problems such as multiple solutionselection, nonlinear error, singularity tool axis etc. Because of such problems, evenwell-established toolpath may cause interference and collision, bringing hazardous results tomachining equipment and NC operators.This research focuses on half-closed integral impellers, analyzing tool axis variation alongtoolpath, as well as constraints between rotating movement of the machine tool andmachining position limits, establishing post-processing methods for ensuring motioncontinuity and suppressing nonlinear error, and developing inverse kinematics and machiningsimulation software, in order to overcome the low efficiency of manual adjustment and thedifficulty of considering tool axis singularity during tool path generation process. Thefollowing research is performed:(1) To solve the collision problems caused by improper selection of inverse kinematicssolution, an automatic solution selection method is proposed considering both tool axisconfiguration and machining axes’ motion limits, so that motion continuity is guaranteed.(2) To effectively suppressing the nonlinear error, two traditional nonlinear error suppressingmethods are reviewed, and a novel cone based post-processing method is proposed. Suddenrotation of the machine axe caused by singularity configuration is thus solved so thatmachining efficiency and precision is guaranteed.(3) Cutter location simulation and machine tool movement simulation is studied. Based oncutter location data, a tolerance based movement uniformly discretization method is employedfor interference detection and NC program verification.Algorithms proposed in this thesis are integrated into new software design, includingoptimized post-processing software, feasible cone cutter location generation andpost-processing module, and SaberMill five-axis NC verification software. Experiments fordemonstrating the effectiveness of these software or module are given.