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Five-axis CNC programming of air compressor rotor

Flow chart of using UG to process air compressor rotors. When using UG to program the rotor CNC, the flow chart shown in Figure 5 is usually used as a guide to create the tool position trajectory for each operation and throughout the entire processing process.

1. Create a parent node group

1. Under the tool node, add all the tools used for processing and set their tool parameters;

2. Under the geometry node, select the blank, set the processing coordinate system, and select the avoidance geometry as the rotor entity;

3. Under the method node, set the display color of the spindle speed, feed rate and tool path during roughing, semi-finishing and finishing.

2. Grooving processing

The grooved processing of the impeller airflow passage extracts the flow passage surface, and the U and V parameter lines are shown in Figure 6(a). Because the processing of the impeller channel needs to be along the air flow direction, the U and V parameter lines of the flow channel are rearranged so that the U parameter or V parameter line is along the air flow direction. Because of the particularity of this flow channel surface, after readjusting the U and V parameters, the flow channel surface was divided into three surfaces. The rearranged V parameter line is shown in Figure 6(b), which is along the airflow direction.

(1) The front end curved surface of the flow channel (surface 1 in Figure 6(b)) is processed using variable axis curved surface contour milling (Variable Contour). The deeper the processing depth, the more serious the interference. A tool axis control method is used. It may not be suitable, so it is divided into two cutter axis control methods.

One is: Normal to Drive (for upper half layer processing),

One type is: Toward Point (used for lower half layer processing).

1. To process the upper half layer, the program parameters are set as follows:

1) The Drive Method uses Surface Area;

2) The driving geometry uses the front end surface of the flow channel, which is surface 1 in Figure 6(b);

3) Establish an avoidance geometry and use the entire part as the avoidance geometry. If there is interference, the tool will automatically retract. Generally, automatic tool retraction is used during rough machining to avoid interference.

4) Rough machining, select Tolerance=0.1mm for line spacing;

5) The tool axis control mode is: Normal to Drive;

6) The Start step and End step of Surface% in the cutting area are both set to: 50, which means cutting once in the middle of the processing surface;

7) Set Non-Cutting, that is, non-cutting motion, and choose to advance and retreat the tool along the tool axis;

8) Under Cutting, set the Stock allowance: 7mm; set Multiple passes (multi-layer processing), and the cutting depth of each layer is 0.5mm.

2. To process the lower half layer, the program parameters are set as follows:

1) The tool axis control method is: Toward Point;

2) Under Cutting, set the Stock allowance: 0.2mm; set Multiple passes (multi-layer processing), and the cutting depth of each layer is 0.5mm.

3) Other parameter settings are the same as the procedure for processing the upper half layer. Because the key to variable-axis curved surface contour milling is to select the tool axis control method, subsequent processing only explains the tool axis control method.

(2) The curved surface at the left end of the flow channel (surface 2 in Figure 6(b)) is processed using variable axis curved surface contour milling. To process this curved surface, one of the tool axis control methods is Normal to Drive (used for the above Half part processing), one is Relative to Drive (for lower part processing). (3) Processing of the curved surface at the right end of the flow channel (surface 3 in Figure 6(b)). The curvature of this surface changes very gently. The angle between the normal direction of each point on the curved surface and the blade surface is close to 0º. Therefore, the selected surface for processing this curved surface The tool axis control mode is Normal to Drive. The generated machining tool path is shown in Figure 7.

3. Groove expansion processing of impeller airflow channel

The groove expansion tool path is similar to grooving processing, except that the Start step of Surface% in the cutting area is set to: 0, End step: 100, which means cutting the entire flow channel surface, and the generated tool path is shown in Figure 8.

Further expansion of the groove and rough machining of the blade. After the expansion of the groove, most of the allowance of the runner has been processed. In order to ensure a uniform machining allowance before finishing and improve the final surface processing quality, this step is to continue the expansion of the groove and rough processing of the blade. processing. To process the driving surface, select the offset surface of the blade, as shown in Figure 9. The simulation results after rough machining of the flow channel and blade are shown in Figure 10.

 

4. Finishing of blades

The finishing machining of the primary and secondary blades of the rotor (suction surface, pressure surface, front fillet) changes drastically from the suction surface to the pressure surface. Therefore, the suction surface, pressure surface and front fillet are processed separately.

The primary and secondary blade profiles are similar, and the processing parameters are similar. The following are the general parameter settings for blade finishing.

1. Drive geometry selection to process the surface;

2. The tool axis control method is: Relative to Drive. The key is to select the parameters Tilt and Lead;

3. Set Non-Cutting, choose to advance along the cutting direction and retract along the direction of the tool axis;

4. Set the finishing Stock to: 0mm; the generated machining tool path is as shown in Figure 11.

5. Finishing of blade root filleting

Because the curvature of the rounded corner changes drastically, using Relative (Normal) To Drive to control the direction of the cutter axis is easy to interfere with other blades. Therefore, the cutter axis control method for large and small blades is: Toward Line. Sometimes only one control cutter axis line is used. , it is still not possible to control the processing of a complete curved surface, and several control lines may need to be selected. The left side of the large blade is rounded to process the tool path as shown in Figure 12, and the left side of the small blade is rounded to process the tool path as shown in Figure 13.

UG can be used to realize CNC machining programming of complex micro integral impellers, with good machining results.

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