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外文翻译--三轴和五轴表面仿形铣削加工 英文版.pdf

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外文翻译--三轴和五轴表面仿形铣削加工 英文版.pdf

THREEANDFIVEAXESMILLINGOFSCULPTUREDSURFACESRBAPTISTAA,,1,JFANTUNESIMO˜ESB,2AINSTITUTOSUPERIORTECNICO,TECHNICALUNIVERSITYOFLISBOA,LIBSON,PORTUGALBESCOLASUPERIORDETECNOLOGIA/INSTPOLITECNICODESETUBAL,SCHOOLOFTECHNOLOGY/POLYTECHNICINSTITUTEOFSETUBAL,SETUBAL,PORTUGALACCEPTED17DECEMBER1999ABSTRACTTHEAIMOFTHISWORKISTHEANALYSISOFTHEINFLUENCEOFTHEMILLINGPARAMETERSONTHESURFACEFINISHTHISWORKISOFINTERESTTOBOTHSCIENCEANDINDUSTRYONONEHAND,ITTRIESTOREDUCETHEMANUALPOLISHINGTIME,WHICHREPRESENTSAHIGHPERCENTAGEOFTHEPRODUCTIONTIMEOFMOULDSONTHEOTHERHAND,WHILETHELITERATUREMAINLYREFERSTOSTEELMOULDS,THISWORKWASCARRIEDOUTONALUMINIUMBECAUSEOFITSADVANTAGESFORMACHININGANDITSSUITABILITYFORMOULDSINSMALLBATCHPRODUCTIONTHEMANUFACTURERSAREINTERESTEDINTHEPRODUCTIONOFALUMINIUMMOULDSA5AXISCNCMILLINGMACHINEWASUSEDFORTHESURFACEFINISHINGOFSEVERALPARTS,PREVIOUSLY3AXISMACHINED,WITHINEQUALCUTTINGCONDITIONSDIFFERENTMACHININGCONDITIONSON3AND5AXESFINISHINGOPERATIONSWERETESTEDTHECOMPARISONOFTHERESULTSALLOWSTOCONCLUDETHATABETTERSURFACEFINISHISACHIEVEDWITH5AXISMILLINGUSINGANENDMILLINCLINEDINTHEFEEDINSTEADOFTHETRADITIONAL3AXISMILLINGWITHABALLNOSECUTTERTHEAPPLICATIONOFTHEDESIGNOFEXPERIMENTSTECHNIQUETOGETHERWITHMULTIPLELINEARREGRESSIONENABLESTHEESTABLISHMENTOFAMATHEMATICALMODELOFTHEPROCESSTHATGIVESTHEPROCESSPARAMETERVALUESTHATLEADTOTHEMINIMUMMACHININGTIMEINORDERTOACHIEVEACERTAINROUGHNESSKEYWORDSTHREEANDFIVEAXESMILLING;TOOLTYPEANDORIENTATION;SURFACEFINISHANDMACHININGTIME1INTRODUCTIONTHEDEVELOPMENTOFTHEAERONAUTICANDAUTOMOBILEINDUSTRIESBROUGHTNEWTECHNOLOGICALCHALLENGES,RELATEDTOTHEGROWINGCOMPLEXITYOFTHEPRODUCTSANDTHENEWGEOMETRIESMODELLEDINCADSYSTEMSTHESEMORECOMPLEXGEOMETRIESIMPOSENEWCHALLENGINGMANUFACTURINGSITUATIONSFORTHEMILLINGOFMOULDSANDSTAMPINGTOOLSTHISISANIMPORTANTREASONFORTHEDEVELOPMENTOFNEWMILLINGTECHNOLOGY,NAMELY5AXISMILLINGTHESTUDYOFTHESENEWMILLINGTECHNIQUEISVERYIMPORTANTINORDERTOIDENTIFYINWHATCONDITIONSEACHONEOFTHESETECHNIQUESCANGIVETHEBESTRESULTMANUALPOLISHINGOFSCULPTUREDSURFACESISALMOSTNECESSARYTOOBTAINTHEDESIREDSURFACEROUGHNESSTHISKINDOFOPERATIONISACONSEQUENCEOFTHEINABILITYOFTHEMILLINGPROCESSTOACHIEVEECONOMICALLYTHEREQUIREDSURFACEQUALITYANDINOURDAYSISMOREANDMOREAFFECTEDBYTHEDECREASINGNUMBEROFQUALIFIEDWORKERSTHE5AXISMILLINGIS,NOW,ONEOFTHETECHNIQUESTHATCANGIVEENORMOUSADVANTAGESINMACHININGOPERATIONS,POTENTIALFORSIGNIFICANTREDUCTIONOFTHEREQUIREDMANUALFINISHINTHISPAPER,THEROUGHNESSRAOFTHEMACHININGSURFACEISRELATEDTOTHEOPERATINGPARAMETERS,APPEALINGTOAMATHEMATICALSTATISTICMODELTHEPARTGEOMETRYWASSELECTEDINORDERTOREPRESENT,INABLOCKOFSMALLDIMENSIONS,ALLTHEDIFFERENTGEOMETRIESTHATCANBEFOUNDINMOULDSANDSTAMPINGTOOLSTHEEQUATIONSRELATINGTHEROUGHNESSLEVELTOTHEMACHININGCONDITIONSFEEDPERTOOTHANDSTEPOVER,ONPARTICULARPARTAREA,WEREDETERMINEDASEXPECTED,THEDEVELOPEDMATHEMATICALMODELEXPRESSESADEQUATELYTHEEXPERIMENTALRESULTSANDENABLESTHEUTILISATIONOFANOPTIMISATIONCRITERION,MACHININGTIMEINTHISCASETHISFACTEMPHASISESTHEIMPORTANCEOFTHEMATHEMATICALMODELSTOESTABLISHTHEMACHININGPARAMETERSAIMINGTHEOPTIMALUSEOFTHERESOURCESTHEEXPERIMENTALWORKPLANNINGANDTHEANALYSISOFTHERESULTSWEREDONEACCORDINGTOTHE‘‘DESIGNOFEXPERIMENTS’’METHOD2EXPERIMENTALWORKTHISWORKTARGETSASPECIFICINDUSTRIALPROBLEMTHEFINISHINGOFSCULPTUREDSURFACEBYMILLINGOPERATIONTHEJOURNALOFMATERIALSPROCESSINGTECHNOLOGY1032000398–403CORRESPONDINGAUTHOR1MSO,ASSISTANTPROFESSOROFTHEIST2CP,ASSISTANTOFTHEESTWORKCARRIEDOUTCONSISTEDONTHECOMPARISONOFTHEPERFORMANCEOF5AXISMILLINGCOMPARATIVETOTHE3AXISMILLINGOFSCULPTUREDSURFACESALLOFTHEPROCESSVARIABLESHAVEBEENIDENTIFIEDANDTHEMOSTRELEVANTONESWERESELECTEDFORSTUDYTHEFINALOBJECTIVEISTOQUANTIFYTHEIRVALUESINORDERTOOBTAINTHEMINIMUMMACHININGTIMEFORAFIXEDROUGHNESS21IDENTIFICATIONANDSELECTIONOFPROCESSVARIABLESTHEPROCESSPARAMETERSSELECTEDFORTHEEXPERIMENTALWORKWERETHESTEPOVER,THEFEEDPERTOOTH,THEFEEDDIRECTIONANDTHE3ANDTHE5AXESMILLINGTECHNOLOGYASTHEMILLINGMACHINEHADALOWROTATIONLIMITOF4200RPM,ANDTHETOOLCOULDWORKINHIGHERSPEED,ITWASDECIDEDTOKEEPTHECUTTINGSPEEDCONSTANTALSO,THETOOLDIAMETERWASKEPTCONSTANTANDASMALLDIAMETEROF10AND12MM,SUCHASOCCURSWITHINDUSTRIALPRACTICE,WERECHOSENINORDERTOAVOIDGEOMETRICALINTERFERENCEBETWEENTHETOOLANDTHEPARTTHECUTTINGDEPTHWASALSOMAINTAINEDCONSTANTNOTONLYTOREDUCETHENUMBEROFVARIABLESBUTALSOBECAUSEINFINISHINGOPERATIONSTHEDEPTHISALWAYSSMALL22EQUIPMENTTHEMILLINGOPERATIONSWEREPERFORMEDONA5AXISCNCMILLINGMACHINEHERMLEUWF1202HEQUIPPEDWITHANHEIDENHAINTNC425CNCCONTROLLERMASTERCAMVERSION554WASUSEDTOCREATETHECNCPARTPROGRAMSMULTISURFMODULEFOR3AXISANDFLOWLINEMODULEFOR5AXIS,WEREUSED3EXPERIMENTALSETUPTHEEXPERIMENTALWORKWASDIVIDEDINTOTWOPHASESTHEFIRSTPHASEWASTHE3AXISMILLINGANALYSIS,WITHABALLNOSEMILLTHESECONDPHASEWASTHE5AXISMILLING,WITHTWOKINDSOFTOOLS,ABALLNOSEANDANENDMILLTHECONTROLPARAMETERSCONSIDEREDWERETHESURFACEROUGHNESS,DIMENSIONALACCURACYANDSHAPEOFTHEPARTGEOMETRY,ANDMACHININGTIMETHEPART’SGEOMETRYHASFOURDIFFERENTSHAPESACONVEXSHAPE,ACONCAVESHAPE,ANHORIZONTALPLANESHAPEANDANINCLINEDPLANESHAPEFIG1ALTHOUGHTHISSTUDYISABOUT5AXISMILLING,THEPARTHADACURVATUREONLYINONEDIRECTIONTHEDOUBLECURVATUREWILLBRINGONLYM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