Abstract: To solve difficulties of Cutter-Workpiece Engagement(CWE)acquisition and spindle speed adjustment for achieving stable milling in the ball-end milling five-axis milling process,a posture stability diagram method based on CWE was proposed.The dynamic cutting force model considering the influence of tool posture and helix angle was established,the initial data of CWE between the tool and workpiece were extracted by NX secondary development,and the CWE under different tool postures was obtained by a coordinate transformation method.The posture stability diagram was constructed using the full discrete method to judge the milling stability under different tool postures.A ball-end milling experiment was carried out in a five-axis machining center through an experimental case to verify the effectiveness and feasibility of this method.On-site processing showed that the test results were in good agreement with the predicted values.

Key words: ball end mill, cutter-workpiece engagement, tool posture, stability prediction, five-axis machining

摘要： 为解决球头刀五轴铣削过程中接触区域获取困难和难以调整主轴转速实现稳定性铣削的问题,提出一种基于接触区域的姿态稳定性图获取方法。首先,建立了考虑刀具姿态与螺旋角影响的动态切削力模型。通过NX二次开发提取刀具与工件接触区域的初始数据,并采用一种坐标变换法获得不同刀具姿态下的接触区域。然后,使用全离散法构建姿态稳定性图判断了在不同刀具姿态下的铣削稳定性。最后,通过实验案例在五轴加工中心中进行球头刀铣削实验,验证了所提方法的有效性与可行性。现场加工表明,实验结果与预测值吻合良好。

关键词: 球头铣刀, 接触区域, 刀具姿态, 稳定性预测, 五轴加工