The machining precision of blades is critical to the service performance of aero engines.The Leading Edge(LE) of high-pressure compressor blades poses a challenge for precision machining due to its thin size, high deg...The machining precision of blades is critical to the service performance of aero engines.The Leading Edge(LE) of high-pressure compressor blades poses a challenge for precision machining due to its thin size, high degree of bending, and significant change of curvature. Aimed at optimizing the machining error, this paper presents a framework that integrates toolpath planning and process parameter regulation. Firstly, an Iterative Subdivision Algorithm(ISA) for clamped Bspline curve is proposed, based on which toolpath planning method towards the LE is developed.Secondly, the removal effect of Cutter Contact(CC) point on the sampling points is investigated in the calculation of grinding dwell time by traversing in u-v space. A global material removal model is constructed for the solution. Thirdly, the previous two steps are interconnected based on the Improved Whale Optimization Algorithm(IWOA), and the optimal parameter combination is searched using the Root Mean Square Error(RMSE) of the machining error as the objective function. Based on this, the off-line programming and robotic grinding experiments are carried out. The experimental results show that the proposed method with error optimization can achieve 0.0143 mm mean value and 0.0160 mm standard deviations of LE surface error, which is an improvement of32.5% and 33.9%, respectively, compared with previous method.展开更多
The Blade Integrated Disk(Blisk) is one of the key components in the aero-engine, it is generally manufactured by the multi-axis milling and almost 90% raw materials are removed. To avoid the full immersion of a cutte...The Blade Integrated Disk(Blisk) is one of the key components in the aero-engine, it is generally manufactured by the multi-axis milling and almost 90% raw materials are removed. To avoid the full immersion of a cutter in the rough machining of a blisk channel, the trochoidal milling is a promising strategy since it can keep a small immersion angle in the rough milling process while maintaining the high machining efficiency. However, while toolpaths are being planned for the trochoidal milling process, the conventional methods are mainly for the planar machining area with fixed tool orientations, which cannot be used for complex channels where the multi-axis machining should be employed. To this end, this paper presents a four-axis trochoidal toolpath planning method with a ball-end cutter, and thus the blisk channel can be machined efficiently.For this to happen, the trochoidal paths are planned in the parametric domain and then mapped into the physical domain, with tool orientations controlled by the quaternion interpolation method to have smooth tool movement along the toolpaths. Both geometric simulation and physical milling experiments of the proposed method have convincingly demonstrated the validation of the proposed method.展开更多
Driven by the ever increasing demand in function integration,more and more next generation high value-added products,such as head-up displays,solar concentrators and intra-ocular-lens,etc.,are designed to possess free...Driven by the ever increasing demand in function integration,more and more next generation high value-added products,such as head-up displays,solar concentrators and intra-ocular-lens,etc.,are designed to possess freeform(i.e.,non-rotational symmetric)surfaces.The toolpath,composed of high density of short linear and circular segments,is generally used in computer numerical control(CNC)systems to machine those products.However,the discontinuity between toolpath segments leads to high-frequency fluctuation of feedrate and acceleration,which will decrease the machining efficiency and product surface finish.Driven by the ever-increasing need for high-speed high-precision machining of those products,many novel toolpath interpolation and smoothing approaches have been proposed in both academia and industry,aiming to alleviate the issues caused by the conventional toolpath representation and interpolation methods.This paper provides a comprehensive review of the state-of-the-art toolpath interpolation and smoothing approaches with systematic classifications.The advantages and disadvantages of these approaches are discussed.Possible future research directions are also offered.展开更多
Sharp corners usually are used on glass contours to meet the highly increasing demand for personalized products,but they result in a broken wheel center toolpath in edge grinding.To ensure that the whole wheel center ...Sharp corners usually are used on glass contours to meet the highly increasing demand for personalized products,but they result in a broken wheel center toolpath in edge grinding.To ensure that the whole wheel center toolpath is of G1 continuity and that the grinding depth is controllable at the corners,a transition toolpath generation method based on a velocity-blending algorithm is proposed.Taking the grinding depth into consideration,the sharp-corner grinding process is planned,and a velocity-blending algorithm is introduced.With the constraints,such as traverse displacement and grinding depth,the sharp-corner transition toolpath is generated with a three-phase motion arrangement and with confirmations of the acceleration/deceleration positions.A piece of glass with three sharp corners is ground on a three-axis numerical-control glass grinding equipment.The experimental results demonstrate that the proposed algorithm can protect the sharp corners from breakage efficiently and achieve satisfactory shape accuracy.This research proposed a toolpath generation method based on a velocity-blending algorithm for the manufacturing of personalized glass products,which generates the transition toolpath as needed around a sharp corner in real time.展开更多
In particular, a fair amount of the machining time may be spent in rough cutting process when a large portion of the raw material has to be removed. Therefore, an algorithm for generating the toolpath for rough cuttin...In particular, a fair amount of the machining time may be spent in rough cutting process when a large portion of the raw material has to be removed. Therefore, an algorithm for generating the toolpath for rough cutting is suggested in the paper. The algorithm is based on an extended tracing method for plane/surface intersection is proposed for smooth surface. A 2.5D milling or parallel offset machining is to be used to significantly improve producitvity and lead to lower production costs for the sculptured multi surfaces part rough machining..展开更多
Cast blanks with large-scale free form surfaces are very difficult tomanufacture because of significant casting distortions. It is concerned that the development andapplication of a hogging algorithm for preparing the...Cast blanks with large-scale free form surfaces are very difficult tomanufacture because of significant casting distortions. It is concerned that the development andapplication of a hogging algorithm for preparing the blanks for an extended rough cutting. Theprocedure includes three main phases. They are the reconstruction of the free form surface withscattered points based on a special Hermite's interpolation, intersection of curved surfaces todefine the hogging areas, and the tool path planning. The result shows that the algorithm is greatlyvalid in reducing the invalid tool paths so that the work efficiency can be improved remarkably.展开更多
Tool path generated by space-filling curve always turns frequently causing trembling to machine,reducing toollife and affecting workpiece quality. Length and generation time of tool paths are both relatively long. In ...Tool path generated by space-filling curve always turns frequently causing trembling to machine,reducing toollife and affecting workpiece quality. Length and generation time of tool paths are both relatively long. In order to solve these problems,a toolpath generation method of NC milling based on space-filling curve is proposed. First,T-spline surface is regarded as the modeling surface,the grid,which is based on the limited scallop-height,can be got in the parameter space,and the influence value of grid node is determined. Second,a box is defined and planned,and the tool paths are got preliminarily,which is based on minimal spanning tree; Finally,based on an improved chamfering algorithm,the whole tool paths are got. A simulation system is developed for computer simulation,and an experiment is carried out to verify the method. The results of simulation and experiment show that the method is effective and feasible,and length and time of the tool paths are reduced.展开更多
Smooth transitions between two adjacent five-axis toolpaths can reduce feedrate fluctuation,improving machining quality and efficiency.Hybrid robots’flexibility to adjust the orientation is advantageous in five-axis ...Smooth transitions between two adjacent five-axis toolpaths can reduce feedrate fluctuation,improving machining quality and efficiency.Hybrid robots’flexibility to adjust the orientation is advantageous in five-axis machining,but their kinematic issues raise challenges for toolpath smoothing.This paper proposes a G3continuous toolpath smoothing method for a hybrid robot.B-splines in the machine coordinate system(MCS)are inserted at corners to synchronize five-axis transitions.The transition errors of the tool position and orientation paths are estimated with the golden section method.These approximation errors are constrained by adaptively modifying the B-splines,i.e.,adding anchor points and optimizing the control points.A bisection search method is proposed for these geometric modifications,guaranteeing the user-defined error tolerance limit.Compared to the method based on the workpiece coordinate system(WCS),the proposed framework generates a smoother trajectory under the same error tolerance limit.Simulations and experiments are provided to validate the effectiveness.展开更多
基金supported by the National Natural Science Foundation of China (No. 52075059)Graduate Scientific Research and Innovation Foundation of Chongqing (No. CYB23021)the Innovation Fund of Aero Engine Corporation of China (No. ZZCX-2022-019)。
文摘The machining precision of blades is critical to the service performance of aero engines.The Leading Edge(LE) of high-pressure compressor blades poses a challenge for precision machining due to its thin size, high degree of bending, and significant change of curvature. Aimed at optimizing the machining error, this paper presents a framework that integrates toolpath planning and process parameter regulation. Firstly, an Iterative Subdivision Algorithm(ISA) for clamped Bspline curve is proposed, based on which toolpath planning method towards the LE is developed.Secondly, the removal effect of Cutter Contact(CC) point on the sampling points is investigated in the calculation of grinding dwell time by traversing in u-v space. A global material removal model is constructed for the solution. Thirdly, the previous two steps are interconnected based on the Improved Whale Optimization Algorithm(IWOA), and the optimal parameter combination is searched using the Root Mean Square Error(RMSE) of the machining error as the objective function. Based on this, the off-line programming and robotic grinding experiments are carried out. The experimental results show that the proposed method with error optimization can achieve 0.0143 mm mean value and 0.0160 mm standard deviations of LE surface error, which is an improvement of32.5% and 33.9%, respectively, compared with previous method.
基金supported by the China National Science and Technology Major Project(No.2015ZX04001202)
文摘The Blade Integrated Disk(Blisk) is one of the key components in the aero-engine, it is generally manufactured by the multi-axis milling and almost 90% raw materials are removed. To avoid the full immersion of a cutter in the rough machining of a blisk channel, the trochoidal milling is a promising strategy since it can keep a small immersion angle in the rough milling process while maintaining the high machining efficiency. However, while toolpaths are being planned for the trochoidal milling process, the conventional methods are mainly for the planar machining area with fixed tool orientations, which cannot be used for complex channels where the multi-axis machining should be employed. To this end, this paper presents a four-axis trochoidal toolpath planning method with a ball-end cutter, and thus the blisk channel can be machined efficiently.For this to happen, the trochoidal paths are planned in the parametric domain and then mapped into the physical domain, with tool orientations controlled by the quaternion interpolation method to have smooth tool movement along the toolpaths. Both geometric simulation and physical milling experiments of the proposed method have convincingly demonstrated the validation of the proposed method.
基金the support from the UK Engineering and Physical Sciences Research Council (EPSRC) under the program (No. EP/K018345/1)the International Cooperation Program of China (No. 2015DFA70630)
文摘Driven by the ever increasing demand in function integration,more and more next generation high value-added products,such as head-up displays,solar concentrators and intra-ocular-lens,etc.,are designed to possess freeform(i.e.,non-rotational symmetric)surfaces.The toolpath,composed of high density of short linear and circular segments,is generally used in computer numerical control(CNC)systems to machine those products.However,the discontinuity between toolpath segments leads to high-frequency fluctuation of feedrate and acceleration,which will decrease the machining efficiency and product surface finish.Driven by the ever-increasing need for high-speed high-precision machining of those products,many novel toolpath interpolation and smoothing approaches have been proposed in both academia and industry,aiming to alleviate the issues caused by the conventional toolpath representation and interpolation methods.This paper provides a comprehensive review of the state-of-the-art toolpath interpolation and smoothing approaches with systematic classifications.The advantages and disadvantages of these approaches are discussed.Possible future research directions are also offered.
基金Supported by National Key R&D Program of China(Grant No.2017YFB0309800)National Natural Science Foundation of China(Grant No.51405445)
文摘Sharp corners usually are used on glass contours to meet the highly increasing demand for personalized products,but they result in a broken wheel center toolpath in edge grinding.To ensure that the whole wheel center toolpath is of G1 continuity and that the grinding depth is controllable at the corners,a transition toolpath generation method based on a velocity-blending algorithm is proposed.Taking the grinding depth into consideration,the sharp-corner grinding process is planned,and a velocity-blending algorithm is introduced.With the constraints,such as traverse displacement and grinding depth,the sharp-corner transition toolpath is generated with a three-phase motion arrangement and with confirmations of the acceleration/deceleration positions.A piece of glass with three sharp corners is ground on a three-axis numerical-control glass grinding equipment.The experimental results demonstrate that the proposed algorithm can protect the sharp corners from breakage efficiently and achieve satisfactory shape accuracy.This research proposed a toolpath generation method based on a velocity-blending algorithm for the manufacturing of personalized glass products,which generates the transition toolpath as needed around a sharp corner in real time.
文摘In particular, a fair amount of the machining time may be spent in rough cutting process when a large portion of the raw material has to be removed. Therefore, an algorithm for generating the toolpath for rough cutting is suggested in the paper. The algorithm is based on an extended tracing method for plane/surface intersection is proposed for smooth surface. A 2.5D milling or parallel offset machining is to be used to significantly improve producitvity and lead to lower production costs for the sculptured multi surfaces part rough machining..
基金This project is supported by Visiting Scholar Foundation of Key Laboratory in University, Ministry of Education of China.
文摘Cast blanks with large-scale free form surfaces are very difficult tomanufacture because of significant casting distortions. It is concerned that the development andapplication of a hogging algorithm for preparing the blanks for an extended rough cutting. Theprocedure includes three main phases. They are the reconstruction of the free form surface withscattered points based on a special Hermite's interpolation, intersection of curved surfaces todefine the hogging areas, and the tool path planning. The result shows that the algorithm is greatlyvalid in reducing the invalid tool paths so that the work efficiency can be improved remarkably.
基金Supported by the National Natural Science Foundation of China(No.51575143)
文摘Tool path generated by space-filling curve always turns frequently causing trembling to machine,reducing toollife and affecting workpiece quality. Length and generation time of tool paths are both relatively long. In order to solve these problems,a toolpath generation method of NC milling based on space-filling curve is proposed. First,T-spline surface is regarded as the modeling surface,the grid,which is based on the limited scallop-height,can be got in the parameter space,and the influence value of grid node is determined. Second,a box is defined and planned,and the tool paths are got preliminarily,which is based on minimal spanning tree; Finally,based on an improved chamfering algorithm,the whole tool paths are got. A simulation system is developed for computer simulation,and an experiment is carried out to verify the method. The results of simulation and experiment show that the method is effective and feasible,and length and time of the tool paths are reduced.
基金supported by the National Natural Science Foundation of China(Grant Nos.51935010 and 52275501)。
文摘Smooth transitions between two adjacent five-axis toolpaths can reduce feedrate fluctuation,improving machining quality and efficiency.Hybrid robots’flexibility to adjust the orientation is advantageous in five-axis machining,but their kinematic issues raise challenges for toolpath smoothing.This paper proposes a G3continuous toolpath smoothing method for a hybrid robot.B-splines in the machine coordinate system(MCS)are inserted at corners to synchronize five-axis transitions.The transition errors of the tool position and orientation paths are estimated with the golden section method.These approximation errors are constrained by adaptively modifying the B-splines,i.e.,adding anchor points and optimizing the control points.A bisection search method is proposed for these geometric modifications,guaranteeing the user-defined error tolerance limit.Compared to the method based on the workpiece coordinate system(WCS),the proposed framework generates a smoother trajectory under the same error tolerance limit.Simulations and experiments are provided to validate the effectiveness.
