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研究生: 林聰徳
Tsong-der Lin
論文名稱: 五軸NC加工路徑之直線與圓弧插補
Linear and Circular Interpolation of Five-axis NC Tool Paths
指導教授: 林清安
Ching-An Lin
口試委員: 賴景義
J. Y. Lai
姚宏宗
none
周明
none
謝文賓
none
楊宏智
none
學位類別: 博士
Doctor
系所名稱: 工程學院 - 機械工程系
Department of Mechanical Engineering
論文出版年: 2013
畢業學年度: 101
語文別: 中文
論文頁數: 170
中文關鍵詞: 五軸NC加工後處理插補CAM
外文關鍵詞: 5-axis NC machining, post-processing, interpolation, CAM
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  • 五軸NC加工機比三軸NC加工機多了兩個旋轉軸,因此在加工時除了線性軸移動之外,還可以有兩個軸在旋轉,使得它的複雜度大幅增加。五軸加工機不但適用於具有高複雜度及高精密度的零件加工,在業界更被公認為是提升產品附加價值的利器,這也使得此產業在面臨轉型時,各廠商所急欲投入研究發展的頂尖機種,然而也正因為其複雜度的大幅增加,使得在切削過程中可能產生一些令人意想不到的路徑變化。由於五軸加工路徑的後處理法則與控制器的品質息息相關,因此本論文針對五軸加工路徑的CAM插補作深入的探討,提出能提升CAM插補效能的方法。
    本研究首先探討會導致五軸加工刀具路徑偏離的因素,接著提出換組操作法則及五軸等弦高直線插補法來修正刀具路徑的偏離,然後再利用研究直線插補的實際經驗,繼續研究更複雜的五軸圓弧插補法,以增進五軸圓弧加工時的精密度,最後再以兩個五軸加工的標竿案例,分別利用五軸等弦高插補法與商用CAM軟體進行插補點數量之比較。比較的結果證明:本論文所提出的五軸等弦高直線及圓弧插補法確實可修正五軸刀具路徑的偏離、提升資料處理的效能,以及增強五軸加工的後處理能力。


    A 5-axis NC machine tool has two additional rotational axes as compared to a 3-axis NC machine tool. Therefore, it creates two additional rotational movements in addition to the linear movement generated during machining, which significantly increases the complexity of the machine. A 5-axis machine tool is not only suitable for using in machining parts that are highly complex and highly precise, it is also recognized by the industry as a good tool for enhancing the added-value of a product. This is why 5-axis machines are the model of choice that vendors are eager to invest in for research and development when facing the moment of industrial restructuring. However, because of its complexity, the cutting process may produce some unexpected path deviations as a result. Since the capability of post processing for 5-axis tool paths are closely affected by the quality of the controller, this study is devoted to in-depth exploration of CAM interpolation of 5-axis tool paths and to finding ways to upgrade the capability of CAM interpolators.
    This research first explores the factors contributing to tool path deviation when performing 5-axis machining, and then proposes a solution-switch principle and a constant-chord linear interpolation method to solve the path deviation problem. With the linear interpolation experience, this research proceeds to the study of circular interpolation method to improve the accuracy of 5-axis circular machining. Finally, two case studies are used to compare the total interpolation points generated by CAM software and by the constant-chord method proposed in this thesis. The system implementation shows: using the proposed 5-axis linear and circular interpolation methods can indeed correct 5-axis tool path deviations, and enhance the post-processing capability of 5-axis machining.

    摘要II AbstractIII 誌謝V 目錄VI 圖目錄IX 符號索引XVI 表目錄XVII 第1章緒論1 1-1研究背景1 1-2研究動機1 1-3研究目的與方法2 1-4論文架構4 第2章文獻探討7 2-1五軸加工之座標轉換7 2-2刀具路徑的產生10 2-3插補法14 2-4傳統CAM插補器所存在的問題18 2-4-1實例探討118 2-4-2實例探討225 第3章五軸加工之座標轉換公式探討32 3-1CL data轉換為NC data33 3-2NC data轉換為CL data36 3-3路徑偏離現象的探討38 3-3-1路徑偏離案例138 3-3-2路徑偏離案例239 第4章造成五軸刀具路徑偏離之因素45 4-1換組操作45 4-2曲面圓角半徑與球刀半徑的影響54 4-3路徑形態與刀軸向量對刀具路徑的影響64 第5章五軸等弦高直線插補法74 5-1等間距插補法之缺點75 5-2五軸等弦高直線插補法之原理77 5-33D圓弧弦高公式之推導81 5-4插補點的刀軸規劃82 5-5五軸等弦高直線插補法85 第6章五軸圓弧插補法104 6-1五軸圓弧切削的誤差量及容差界限105 6-2正確與實際切削路徑間的最大偏距107 6-3五軸圓弧插補法之原理108 6-4五軸圓弧公式的推導110 6-5刀軸向量的規劃115 6-6運用五軸圓弧插補法求插補點126 第7章實例驗證146 7-1驗證實例1148 7-2驗證實例2153 第8章結論與未來研究方向160 8-1結論160 8-2未來研究方向161 參考文獻162 作者簡介169

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