中文摘要：

刀具接触区界定了切削过程刀具与工件的相互作用范围,是研究切削力学/动力学的基础,复杂曲面加工的刀具接触区往往呈现不规则几何形状且沿曲线刀具轨迹不断变化。针对球头铣刀复杂曲面多轴加工,提出一种刀具接触区半解析建模方法。基于微元离散和刚体旋转变换的思想,将一般复杂曲面加工看成是一系列微小斜平面加工的组合,并且认为球头铣刀斜平面多轴加工的刀具接触区,可由球头铣刀水平面三轴立铣加工的刀具接触区经刚体旋转变换而得。通过将切削余量材料看成是一系列微厚材料薄层的叠加,构建了球头铣刀水平面三轴立铣加工的刀具接触区解析模型,从而建立球头铣刀复杂曲面多轴加工的刀具接触区半解析模型。仿真实例分析了模型的精度和效率,结果表明该半解析模型能够精确高效地描述复杂曲面多轴加工的刀具接触区。

英文摘要：

CuRer workpiece engagement （CWE）, which defines the interaction region between tool and workpiece, is the basis for studying mechanics and dynamics of cutting. In sculptured surface machining, the CWE usually appears irregular geometry and varies along curve path. A semi-analytical CWE model for multi-axis ball end milling of sculptured surface is presented. With the ideas of differential and rigid-body rotation transformation, general sculptured surface machining is considered as a combination of some small inclined plane machining, and the CWE of inclined plane machining can be obtained by rotating that of horizontal plane machining. By taking the curing allowance material as a combination of some thin parallel slices, an analytical CWE model for ball end milling of horizontal plane is proposed. And thus the CWE model for multi-axis ball end milling＇of sculptured surface machining is obtained. The precision and efficiency of proposed model are investigated by some simulation examples. Simulation results reveal that the developed model can describe CWE in multi-axis ball end milling of sculptured surfaces with high precision and efficiency.