Abstract
For rough machining of a complex narrow cavity,e.g.,a complex blisk channel on an aero-engine,the typically used cutting tools are the slender cylindrical cutter and conical cutter.Nevertheless,as neither of the two is particularly suited for rough machining,wherein the main pur-pose is to remove a large volume as quickly as possible,the machining efficiency is low,especially when the part materials are of hard-to-cut types(e.g.,Titanium-alloy)for which it often takes days to rough machine a blisk.Fortunately,disc machining provides a new and efficient roughing solu-tion,since a disc cutter with a large radius enables a much larger cutting speed and thus a larger material removal rate.However,due to the large radius of the disc cutter,its potential collision with narrow and twisted channels becomes a serious concern.In this paper,we propose a novel two-phase approach for efficiently machining a complex narrow cavity workpiece using a disc-shaped cutter,i.e.,3+2-axis disc-slotting of the channel by multiple layers(rough machining)+five-axis disc-milling of the freeform channel side surfaces(semi-finish machining).Both simulation and physical cutting experiments are conducted to assess the effectiveness and advantages of the pro-posed method.The experimental results show that,with respect to a same cusp-height threshold on the channel side surfaces,the total machining time of the tested part by the proposed method is about only 36％of that by the conventional approach of plunging-milling(for roughing)plus milling by a slender cylindrical cutter(for semi-finishing).
基金项目
Foshan HKUST Projects(FSUST20-SRI09E-FSPM02202007-1)
Project of Hetao Shenzhen-Hong Kong Science and Technology Innovation Cooperation Zone(HZQB-KCZYB-2020083)
National Science and Technology Major Project(J2019-Ⅶ-0001-0141)
NETL
NSTL
万方数据