航空发动机机匣高效加工方法研究

摘要

航空发动机是飞机的核心部件，而机匣则是航空发动机上关键部件之一，其结构极为复杂、制造难度大。机匣从毛坯到成品的加工过程中，大约有70%的材料被切除，其中绝大部分是在机匣的粗加工阶段完成。因此，高效粗加工是实现缩短机匣研制周期的关键。针对机匣结构特点，本文提出采用插铣代替传统侧铣进行高效粗加工，并从机匣零件建模、机匣数控加工工艺、机匣插铣粗加工刀位生成等方面开展了研究。

本文完成的主要工作和取得的成果如下：

1）对机匣的结构进行了分析，并根据机匣的结构特征利用UG软件实现了机匣的实体建模。

2）研究了机匣高效粗加工工艺。针对侧铣与插铣两种加工方式，从切削厚度和刀具挠度两方面进行理论对比分析，并对切削力进行仿真对比分析。结果表明，在相同切除率条件下，插铣径向切削力仅为侧铣的倍，切削过程稳定。

3）根据机匣插铣加工工艺与机匣结构特点，规划了其插铣刀位轨迹，并在UG环境下生成了相应的插铣加工刀位轨迹。此外，以UG为二次开发平台，实现了对插铣线的优化，可有效防止插铣加工过切。

关键词：机匣，高效加工，插铣，刀位轨迹，UG二次开发

ABSTRACT

Aero-engine is the core component of the aircraft, and the casing which is a key part of the engine is difficult to manufacture because its extremely complicate structure. About 70% of the material is removed from blank to finished product, while the most material is removed in rough milling of casing. Therefore, high efficiency roughing of the casing is a key technology to realizing higher efficiency manufacturing and shorter developing cycle. Based on characteristics of casing, plunge milling was proposed to instead of traditional layered flank milling in this paper. And the part modeling, the CNC machining process modeling, the cut-location generation of the plunge milling in rough machining were studied.

The main work and achievements of this thesis are as follows:

1) The casing structure is analyzed, and on this basis, the entity model of casing is established using UG.

2) The efficient rough machining of casing is studied for process planning. Between the side milling and plunge milling methods, cutting thickness and tools deflection were contrasted in theory and the cutting force were contrasted in simulation. The results show that, under the same resection rate, the radial cutting force of the plunge is only times than the side milling, and the process is stable.

3) According to the Plunge milling process and the structure characteristics of casing, the plunge milling cutter path was planned, which is then generated in UG. Additionally, aiming at overcut in plunge milling process, the optimization of the plunge milling line has been implemented using UG secondary development.

Key words: Casing, Efficient processing, Plunge milling, tool path, UG Secondary development

目录

摘要................................................ I ABSTRACT ............................................ II 目录.............................................. III 第一章绪论.. (1)

研究背景 (1)

国内外研究现状 (2)

1.2.1复杂结构类零件粗加工技术 (2)

1.2.2插铣工艺技术 (3)

论文主要内容及章节安排 (5)

第二章机匣造型 (7)

基于特征的建模方法 (7)

建模平台选择 (8)

机匣造型 (9)

2.3.1 机匣模型分析 (9)

2.3.2 机匣实体建模 (10)

第三章机匣数控加工工艺 (15)

工艺规程编制原则 (15)

机匣零件的工艺特征 (15)

机匣加工工艺阶段的划分 (16)

机匣加工工艺路线制定 (16)

机匣粗加工工艺方案分析 (18)

第四章机匣插铣粗加工刀具轨迹 (25)

UG数控加工 (25)

刀具轨迹规划原则 (25)

刀具轨迹生成 (27)

4.3.1加工环境设定 (27)

4.3.2刀具轨迹生成 (27)

4.3.3程序后置处理 (33)

基于UG的插铣线优化 (35)

总结 (38)

致谢 (39)