Research On Removal Volume And Application In Machining Of Typical Features Within Areo Engine Parts

In the wake of the development of science and technology,more and more advanced manufacturing technologies emerges,but the traditional machining technology still occupies an important position in the manufacturing industry.Milling process plays an important role in parts processing.Because of the flexible and controllable tool axis vector,the multi-axis CNC machining has a wide processing range and high efficiency of machining for a variety of complex parts.So it has been widely applied in high-end manufacturing.In this paper,the transient removal volume is extracted in milling process and the five-axis milling is researched by constructing the model of five-axis machining is established and analyzing the cutter-workpiece engagement(CWE).An optimized model of NC programming for milling is presented,and NC programming and processing of aero engine typical parts are conducted.Firstly,based on the relative motion of cutter and workpiece,the model of removal volume was built.Besides the three-dimensional geometric model of the removal volume in the cutting process of the flat end mill and the ball-end mill is introduced.The influence factors of the geometrical shape of the removal volume are analyzed from the geometric perspective.According to these factors,parametric model of the removal volume is established in UG.With parametric modeling,it is easy to modify the model and obtain the models with different parameters quickly,which facilitates the subsequent research and application.Secondly,the multi-axis machining of ball-end milling cutter is studied.The multi-axis machining model of ball-end milling cutter is established.The effects of tool inclination on the machined surface are researched with experimental methods.The CWE and the cutting cross sectional area in the multi-axis machining are studied with the removal volume.The position of CWE and the tool nose and the cutting cross sectional area both change with the rotation angle of the tool,which is analyzed under the different lead angle and tilt angle.The boundary surface equation of the removal volume is established,which is beneficial to study the CWE from the analytical point of view.Then,an optimized model of NC programming for milling is constructed to optimize the NC program generated by CAM software.For the material which needs to be customized,the three-dimensional finite element cutting simulation or cutting experiments are used to obtain the cutting force and cutting temperature with different cutting parameters.During the NC program optimization,the feed rate and cutting speed are optimized according to the range of cutting force or cutting temperature range,which leads to the balanced load and reduced vibration.Finally,NC program of two complex parts of the aero engine(semi-open integral impeller and turbine blisk benchmark)are conducted in hyperMILL.And the processing efficiency,processing quality and other factors are taken into account.The two parts whose material is TC4 titanium alloy are processed with DMU-70V five-axis machining center.The aim of this paper is to provide an effective method for the study of milling and to achieve efficient and high-quality processing of specific parts,which could lay a foundation for in-depth research in future.