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摘要
A new type of data processing model for a ball-end milling process based on biharmonic spline interpolation (BSI) is presented for the first time. The model aims to solve the problem of determining the discrete point number in the conventional machining topography simulation method. The kinematic model of the ball-end milling is established based on the consideration of the tool vibration, and the sweeping point cloud of the cutting edge is generated and extracted based on the servo bounding box. Moreover, the BSI method is introduced to reconstruct the machined surface. In view of the scarcity of prior research studies on the topographical prediction for free-form workpiece surfaces, this study evaluates the prediction model of surface topography of free-form surface milling and extends the application of BSI in the point cloud. The computation error that is caused by the large-scale use of the analytic nonlinear equations in other simulation processes is significantly reduced, and the complex optimization operators that ensure that each microelement of the cutting edge sweeps no more than one grid point within a unit time step are avoided. Correspondingly, this method becomes superior compared to the conventional approximation-processing method of discrete datasuch as IMAGEWAREthereby simplifying data manipulation, improving the calculation accuracy by 7.6%, and reducing the large computation time for the surface topography simulation by linearly expanding the valid data. The effectiveness and accuracy of this algorithm are demonstrated by comparing some computer simulation results with the machining results at different experimental conditions, and some topography evaluation parameters are also analyzed in this study. The shape error (S-ba) and surface roughness (S-a) values of the simulated topographies are compared with those of the measured topographies (error within 15.9%).
- 出版日期2018-12
- 单位深圳信息职业技术学院; 华南理工大学
