The Study of Variational Feed Rate in 4-Axis Machining of Blades

다국어 초록 (Multilingual Abstract)

As a core part of aerospace, space, and steam turbine plants, blades are generally machined via 5-axis linkage processing to satisfy the high precision requirements of the rigorous surface. To save costs in blade machining, many small- and medium-sized enterprises often combine standard 3-axis computer numeric control machines with the automatic indexing turntable. The traditional 4-axis machining method adopts a constant feed rate, which causes overcutting near the leading and trailing edges of the blade because of the rapid changes in tool orientation. To solve this problem, we propose a speed optimization method that utilizes variational speed to ensure that the decomposition velocity and acceleration of each axis do not exceed the allowable values. First, we guarantee the correct tool lead angle. Second, a corrected speed model is established to obtain the component speed of each axis and to determine the constraint conditions of maximum and accelerated speed. Third, a 4-axis post processor for blade processing is developed using Java advanced language combined with the optimization algorithm. The cutting experiment reveals that our proposed speed optimization method effectively controls the precision of the surface profile and overcomes the overcut phenomenon that often occurs in traditional 4-axis machining.

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