Abstract: According to the problem of milling performance prediction and the characteristics of curvature-changing and big-twisted for the complex sculptured surface,a novel method of integrated optimization for analyzing CNC milling performance was presented to evaluate and improve the quality of NC machining efficiency and machining.The integrated optimal model of multi-axis milling for complex sculpture surface was established,which integrated the machining flow such as multi-axis tool path planning,cutting and machine tool motion simulation,cutting force prediction,technological parameter optimization and input output file.Through extracting the calculation parameters from input-output file,the influence of cutting parameters and cutting force on machining efficiency and quality was analyzed and predicted efficiently,and the machining process integration and global optimization for the complex sculpture surface was realized.The presented method was applied to analyze the milling performance of large Francis turbine blade and compared with the production application data,the results suggested that the proposed method was an effective way of analyzing and predicting the CNC milling performance of sculpture surface.

Key words: sculptured surface, milling performance, process integrated model, global optimization

摘要： 针对复杂自由曲面变曲率、大扭曲的特征及其铣削性能难预测的问题,提出加工过程的集成优化的切削性能分析方法,在曲面多轴铣削工作流程中综合评价和提高切削加工效率和质量。建立了自由曲面体零件多轴加工集成优化铣削模型,集成切削加工刀位轨迹计算、切削仿真与机床运动仿真、切削力预测、工艺参数优化工作流程及其输入输出文件,实时从输出文件中解析提取计算结果参数,有效分析预测切削参数与切削力对加工效率和质量的影响,实现复杂自由曲面铣削过程的集成与全局优化。将该方法应用于大型混流式水轮机叶片的数控铣削性能分析,并与生产数据进行对比,进一步验证了所提加工过程集成优化方法可有效分析和预测大型自由曲面的数控铣削性能。

关键词: 复杂自由曲面, 铣削性能, 过程集成, 全局优化