A blade machining method based on side-edge milling compensation of a ball-end milling cutter

Abstract

The present invention belongs to the technical field of numerical control machining, and particularly relates to a blade machining method based on side-edge milling compensation of a ball-end milling cutter. The technical solution of the present invention is as follows: A blade machining method based on side-edge milling compensation of a ball-end milling cutter includes the following steps: 1) Confirm the wear area of the ball-end milling cutter during blade milling; 2) Install a laser tool setter on a five-axis CNC machining center; 3) Use the laser tool setter to measure the ball-end milling cutter in actual machining and calculate the wear value of the ball-end milling cutter after the nth use; 4) Realize in-machine tool compensation on a five-axis CNC machining center. The blade machining method based on side-edge milling compensation of a ball-end milling cutter provided by the present invention uses a laser tool setter to measure the wear value of the ball-end milling cutter and realizes in-machine tool compensation, which can ensure product quality and improve production efficiency.

Description

Technical Field

[0001] The present invention belongs to the technical field of numerical control machining, and particularly relates to a blade machining method based on side-edge milling compensation of a ball-end milling cutter. Background Art

[0002] At present, the blade profiles of aero-engine blades are mostly milled by a five-axis CNC machining center. Since the machining surface is a curved surface, with complex shapes and a small tolerance zone of 0.05 mm, and the machining tool is a ball cutter, it is extremely easy to cause local wear of the tool. Therefore, the compensation control requirements for the tool during the machining process are very strict, and the wear of different edge inclination angles of the tool needs to be compensated into the machining program.

[0003] Currently, the machining method of giving tool compensation based on manual experience is mostly adopted. Affected by uncontrollable human factors, it is easy to cause scrapping of parts. Moreover, it depends on the measurement report of the coordinate measuring machine of the previous product to determine the tool compensation scheme for the next product, which seriously affects the production efficiency. Summary of the Invention

[0004] The present invention provides a blade machining method based on side-edge milling compensation of a ball-end milling cutter, which uses a laser tool setter to measure the wear value of the ball-end milling cutter, realizes in-machine tool compensation, can ensure product quality, and improve production efficiency.

[0005] The technical solution of the present invention is as follows:

[0006] A blade machining method based on side-edge milling compensation of a ball-end milling cutter includes the following steps:

[0007] 1) Confirm the wear area of the ball-end milling cutter during blade milling; use UG or Solidworks to draw a model of the ball-end milling cutter, deflect the ball-end milling cutter model according to the edge inclination angle set in the process specification, and simulate the blade milling process through the ball-end milling cutter model according to the machining allowance set each time in the process specification to confirm the wear area of the ball-end milling cutter, identify the upper and lower edges of the wear area, and find the middle section of the wear area; measure the distances from the upper edge, lower edge, and middle section of the wear area to the tool axis of the ball-end milling cutter, which are K1, K2, and K3 respectively;

[0008] 2) Install a laser tool setter on the five-axis CNC machining center;

[0009] 3) Use the laser tool setter to measure the ball-end milling cutter during actual machining, and calculate the wear value of the ball-end milling cutter after the nth use;

[0010] First, measure the initial tool length of the ball-end milling cutter; select a programming statement with the function of measuring the tool length value with offset in the programming language of the laser tool setter, and the ball-end milling cutter is offset by distances of K1, K2, and K3 respectively, and the initial tool length values of the ball-end milling cutter are measured as L10 , L 20 and L 30 ;

[0011] Then, measure the tool length of the ball-end mill after the nth use; the ball-end mill after the nth use is offset by distances K1, K2, and K3 respectively, and the tool length values of the ball-end mill after the nth use measured by the laser tool setter are L 1n , L 2n and L 3n ;

[0012] After that, calculate the wear value of the ball-end mill after the nth use; the calculation formula is as follows:

[0013] M n = { (L 1n - L 10 ) + (L 2n - L 20 ) + (L 3n - L 30 )} / 3

[0014] In the formula, M n is the wear value of the ball-end mill after the nth use;

[0015] 4) The five-axis CNC machining center realizes in-machine tool compensation; at the output variable value position in the programming system of the five-axis CNC machining center, assign M n as the tool compensation value to the specified tool edge of the five-axis CNC machining center for the next machining.

[0016] Furthermore, in the blade machining method based on the side-edge milling compensation of the ball-end mill, in step 1), in the cross-section of the ball-end mill model passing through the tool axis, a connection line one is formed between the upper edge of the wear area and the ball center of the ball-end mill, a connection line two is formed between the middle cross-section of the wear area and the ball center of the ball-end mill, and a connection line three is formed between the lower edge of the wear area and the ball center of the ball-end mill. The angle between connection line one and connection line two is equal to the angle between connection line two and connection line three.

[0017] The beneficial effects of the present invention are as follows: The present invention uses a laser tool setter to measure the wear value of the ball-end mill and realizes in-machine tool compensation, which can ensure product quality and improve production efficiency. The method of the present invention can be independent of the CMM measurement report of the previous product, which can save the time required to wait for the measurement of the previous product to be completed and reduce the dependence of part machining on the CMM; the method of the present invention no longer requires the operator's experience to adjust the data. The operator only needs to load and unload the part and does not need to manually adjust the tool wear, reducing the situation of product out-of-tolerance or scrapping caused by manual operation errors or judgment errors, and reducing the skill requirement threshold for operators to machine such parts. Description of the Drawings

[0018] Figure 1 It is a schematic diagram of simulating the blade milling process with a ball-end milling cutter model;

[0019] Figure 2 It is a schematic diagram of the wear area of the ball-end milling cutter;

[0020] Figure 3 It is a diagram showing the relationship between the upper edge, lower edge and middle section of the wear area and the center of the ball of the ball-end milling cutter.

[0021] In the figure: 1 is the blade body, 2 is the ball-end milling cutter, 3 is the wear area, 4 is the upper edge, 5 is the lower edge, 6 is the middle section, and 7 is the center of the ball of the ball-end milling cutter. Detailed Implementation Manner

[0022] As Figures 1 - 3 shown, a blade processing method based on the side-edge milling compensation of a ball-end milling cutter includes the following steps:

[0023] 1) Confirm the wear area 3 of the ball-end milling cutter 2 during blade milling; use UG to draw the ball-end milling cutter model, deflect the ball-end milling cutter model according to the rake angle of 45° set in the process specification, and according to the set machining allowance of 0.05 mm each time in the process specification, simulate the blade milling process through the ball-end milling cutter model, confirm the wear area 3 of the ball-end milling cutter 2, identify the upper edge 4 and lower edge 5 of the wear area, and find the middle section 6 of the wear area 3; in the section of the ball-end milling cutter model passing through the tool axis, a connection line one is formed between the upper edge 4 of the wear area 3 and the center of the ball 7 of the ball-end milling cutter 2, a connection line two is formed between the middle section 6 of the wear area 3 and the center of the ball 7 of the ball-end milling cutter 2, and a connection line three is formed between the lower edge 5 of the wear area 3 and the center of the ball 7 of the ball-end milling cutter 2, and the angle between connection line one and connection line two is equal to the angle between connection line two and connection line three; measure the distances from the upper edge 4, lower edge 5 and middle section 6 of the wear area 3 to the tool axis of the ball-end milling cutter 2, which are K1, K2 and K3 respectively;

[0024] 2) Install a laser tool setter on the five-axis CNC machining center;

[0025] 3) Use the laser tool setter to measure the ball-end milling cutter 2 in actual machining and calculate the wear value of the ball-end milling cutter 2 after the nth use;

[0026] First, measure the initial tool length of the ball-end milling cutter 2; keep the C axis of the five-axis CNC machining center at 0, at this time the ball-end milling cutter 2 is in a vertical state with the tool tip facing downwards towards the laser tool setter, select the programming statement with the function of measuring the tool length value with offset in the laser tool setter programming language, and the ball-end milling cutter 2 is offset by the distances of K1, K2 and K3 respectively, and the initial tool length values of the ball-end milling cutter 2 are measured as L 10 、L20 and L 30 ;

[0027] Then, measure the tool length of the ball nose end mill 2 after the nth use; the ball nose end mill 2 after the nth use is offset by distances K1, K2, and K3 respectively, and the tool length values of the ball nose end mill 2 after the nth use measured by the laser tool setter are L 1n , L 2n and L 3n ;

[0028] After that, calculate the wear value of the ball nose end mill after the nth use; the calculation formula is as follows:

[0029] M n ={(L 1n - L 10 ) + (L 2n - L 20 ) + (L 3n - L 30 )} / 3

[0030] In the formula, M n is the wear value of the ball nose end mill after the nth use;

[0031] 4) The five-axis CNC machining center realizes in-machine tool compensation; at the output variable value position in the programming system of the five-axis CNC machining center, assign M n as the tool compensation value to the specified cutting edge of the five-axis CNC machining center, deflect the ball nose end mill 2 to the rake angle of 45°, and perform the machining of the next blade airfoil 1.

Claims

1. A blade machining method based on side edge milling compensation of a ball-end milling cutter, characterized in that, The steps are as follows: 1) Confirm the wear area of the ball-end mill during blade milling; use UG or Solidworks to draw the ball-end mill model, deflect the ball-end mill model according to the blade inclination angle set in the process specification, and simulate the blade milling process through the ball-end mill model based on the machining allowance set in the process specification to confirm the wear area of the ball-end mill, identify the upper and lower edges of the wear area, and find the middle section of the wear area; measure the distances from the upper edge, lower edge, and middle section of the wear area to the tool axis of the ball-end mill, which are K1, K2, and K3 respectively; 2) Install a laser tool setter on the five-axis CNC machining center; 3) Use the laser tool setter to measure the ball-end mill in actual machining and calculate the wear value of the ball-end mill after the nth use; First, measure the initial tool length of the ball-end mill; select the programming statement with the function of measuring the tool length value with offset in the programming language of the laser tool setter. The ball-end mill is offset by distances K1, K2, and K3 respectively, and the measured initial tool length values of the ball-end mill are L 10 , L 20 , and L 30 ; Then, measure the tool length of the ball nose end mill after the nth use; the ball nose end mill after the nth use is offset by distances K1, K2, and K3 respectively, and the tool length values of the ball nose end mill after the nth use measured by the laser tool setter are L 1n , L 2n and L 3n ; After that, calculate the wear value of the ball-end mill after the nth use; the calculation formula is as follows: M n = { (L 1n - L 10 ) + (L 2n - L 20 ) + (L 3n - L 30 )} / 3 where M n is the wear value of the ball end mill after the nth use; 4) The five-axis CNC machining center realizes in-machine tool compensation; at the output variable value position in the programming system of the five-axis CNC machining center, assign the value of M n as the tool compensation value to the specified cutting edge of the five-axis CNC machining center for the next machining operation.

2. The blade machining method based on the side edge milling compensation of the ball end mill according to claim 1, characterized in that In step 1), in the cross-section of the ball-end mill model passing through the tool axis, a connection line one is formed between the upper edge of the wear area and the ball center of the ball-end mill, a connection line two is formed between the middle section of the wear area and the ball center of the ball-end mill, and a connection line three is formed between the lower edge of the wear area and the ball center of the ball-end mill. The angle between connection line one and connection line two is equal to the angle between connection line two and connection line three.

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