基于涡轮盘榫槽拉刀前刀面砂轮磨削位姿及加工特征的磨削轨迹自动生成方法

An automatic generation method for grinding trajectories of the rake face of turbine disk broach based on grinding wheel pose and machining feature recognition

  • 摘要: 涡轮盘矩形槽渐切拉刀前刀面是加工涡轮盘榫槽的重要切削面,前刀面的精确磨削对于刀齿成形质量及使用寿命有着重要影响。由于磨削时砂轮与前刀面易发生干涉,且难以始终与槽底相切加工容屑槽,从而产生形状误差;同时,拉刀多齿多刃的结构特点使得前刀面轨迹生成存在自动化程度低、人机交互频繁的问题。针对以上问题,文章建立拉刀、砂轮坐标系,依据坐标变换矩阵描述了砂轮运动方程并分析了砂轮磨削时的参数约束,计算出砂轮的位置与姿态。基于砂轮位姿采用边界表示的前刀面加工特征识别方法,分析拉刀模型前刀面拓扑关系,通过匹配空间几何关系识别出满足要求的前刀面加工特征。最后,结合砂轮位姿和前刀面加工特征在UG/NX平台二次开发了前刀面磨削轨迹自动生成系统并通过磨削仿真验证出砂轮位姿的正确性及磨削轨迹的适用性。

     

    Abstract: The rake face geometry of rectangular slot progressive broaches employed in turbine disk machining represents a critical cutting surface that directly determines the cutting performance and operational longevity of broaching tools. Due to the fact that interference is prone to occur between the grinding wheel and the rake face during grinding, and it is difficult to consistently machine the chip groove by being tangent to the groove bottom, shape errors are thus generated. Meanwhile, the structural characteristic of a broach having multiple teeth and cutting edges leads to problems such as low automation level and frequent human-machine interaction in generating the trajectory of the rake face. In response to the aforementioned issues, coordinate systems for the broach and the grinding wheel are established. The motion equation of the grinding wheel is described via coordinate transformation matrices, and the parameter constraints during grinding are analyzed. Ultimately, the position and orientation of the grinding wheel are calculated. A feature recognition method based on boundary representation utilizing grinding wheel pose is employed to analyze the topological relationships of the rake face in the broach model, and identify the rake face machining features that meet the requirements by matching spatial geometric relationships. Finally, by integrating the grinding wheel pose and the identified rake face machining features, an automatic generation system for rake face grinding trajectories was developed on the UG/NX platform through secondary development. The correctness of the grinding wheel pose and the applicability of the grinding trajectories were validated through grinding simulation.

     

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