1、 Very high tip velocity - mainly a function of spindle speed and cutter size Small step-over, requiring more machining sequences Constant loading/volume removal rate Avoidance of sharp direction changes 俯垂型：旋转轴不与直线轴相垂直俯垂型：旋转轴不与直线轴相垂直 俯垂型：旋转轴不与直线轴相垂直俯垂型：旋转轴不与直线轴相垂直 五轴机床运动加工此工件时机床、工艺选用？加工此工件时机床、工艺选用？五
2、轴机床运动刀具长度对机床运动的影响刀具长度对机床运动的影响方向的改变对直线轴运动的影响方向的改变对直线轴运动的影响RTCP功能 1.1.RTCPRTCP（Rotary tool center pointRotary tool center point）功能是指刀轴旋功能是指刀轴旋转后为保持刀尖不变五轴转后为保持刀尖不变五轴controllercontroller自动计算并执行线性自动计算并执行线性轴补偿；轴补偿； RTCP ONRTCP ON时，机床各线性轴在旋转后的坐标系时，机床各线性轴在旋转后的坐标系内移动。内移动。 2.2.对于没有对于没有RTCPRTCP功能的五轴机床，后处理输出程序在
3、工功能的五轴机床，后处理输出程序在工件装夹完测量出基准点到机床中心距离之后才能做；对件装夹完测量出基准点到机床中心距离之后才能做；对于有于有RTCPRTCP功能的，后处理输出程序无需考虑工件在机床功能的，后处理输出程序无需考虑工件在机床上的具体位置。上的具体位置。 3.3.RTCP功能Part Position on the tableWith RTCP enabled, the datum of the part can be clocked with easeWithout RTCP enabled, the PowerMILL NC Programmust be output with
4、a Workplane positioned at themachines 0 0 0RTCP功能No Linearization, No RTCPA Linearized or RTCP Enabled Move五轴刀轴矢量控制五轴刀轴矢量控制 1.1.五轴刀轴矢量控制是五轴刀轴矢量控制是CAMCAM系统五轴技术的核心系统五轴技术的核心 2.2.五轴五轴CAMCAM系统给出每个切削点刀具的刀位点（系统给出每个切削点刀具的刀位点（X,Y,Z)X,Y,Z)和刀轴矢量和刀轴矢量( (I,J,K)I,J,K)，五轴后处理器将刀轴矢量（五轴后处理器将刀轴矢量（I,J,KI,J,K）转转化为不同机床的旋
5、转轴需要转动的角度（化为不同机床的旋转轴需要转动的角度（A,B,CA,B,C中的两中的两个）；然后计算出考虑了刀轴旋转之后线性轴需要移动个）；然后计算出考虑了刀轴旋转之后线性轴需要移动的各轴位移（的各轴位移（X,Y,ZX,Y,Z）。）。 3.PowerMILL 3.PowerMILL 五轴刀轴矢量控制的方式丰富灵活，可通五轴刀轴矢量控制的方式丰富灵活，可通过投影方向、点、直线、曲线、平面、曲面来控制，是过投影方向、点、直线、曲线、平面、曲面来控制，是领先的五轴联动加工系统领先的五轴联动加工系统。PMPM刀轴控制刀轴控制前、侧倾角前、侧倾角 侧倾角使刀轴绕切削方向侧倾角使刀轴绕切削方向侧旋一个角
6、度从而避免刀侧旋一个角度从而避免刀尖切削尖切削Lean Angle Lean Angle defines a rotation of the defines a rotation of the Tool axis at right angles Tool axis at right angles to the direction of travelto the direction of travel 正角时为右倾，负角时为正角时为右倾，负角时为左倾左倾Can be positive or Can be positive or negative to indicate a negative to
7、 indicate a right/ left leanright/ left lean 设置侧倾角能有效避免刀设置侧倾角能有效避免刀具干涉具干涉Useful to avoid Useful to avoid collisions when collisions when machining close to machining close to obstaclesobstacles刀轴通过点刀轴通过点From a PointFrom a Point 使刀轴总是通过某一固使刀轴总是通过某一固定点从而避免刀尖切削定点从而避免刀尖切削The tool is aligned so The tool
8、is aligned so that the axis passes that the axis passes through a specified through a specified point with the point with the cutting end cutting end pointing pointing away away from from the pointthe point刀轴通过直线刀轴通过直线Towards a LineTowards a Line 刀轴总是通过直线上的刀轴总是通过直线上的点对齐，从而避免刀尖点对齐，从而避免刀尖切削切削 The tool
9、 is aligned so that The tool is aligned so that the axis passes through a the axis passes through a specified line with the specified line with the cutting end pointing cutting end pointing towards the linetowards the line刀轴总是通过用户定义直线上刀轴总是通过用户定义直线上的点的点Tool axis will always pass Tool axis will always
10、 pass through the user-defined linethrough the user-defined line刀轴通过刀轴通过3 3D D曲线曲线Through a 3D curveThrough a 3D curve 提供了比直线更灵活有提供了比直线更灵活有效的刀轴控制策略效的刀轴控制策略 Offers much more control Offers much more control and flexibility than lineand flexibility than line 刀轴总是通过用户定义刀轴总是通过用户定义的曲线的曲线 Tool axis will a
11、lways pass Tool axis will always pass through the user-defined through the user-defined curvecurvePowerMILLPowerMILL多轴路径策略多轴路径策略 PowerMILLPowerMILL丰富的丰富的三轴粗加工和精加三轴粗加工和精加工刀路策略全部能工刀路策略全部能用于五轴加工。用于五轴加工。 有多种专用的有多种专用的5 5轴加轴加工策略工策略驱动曲面驱动曲面Drive SurfaceDrive Surface 投影方向和刀轴方向由驱投影方向和刀轴方向由驱动曲面（银色面）决定动曲面（银色面）
12、决定 Projection direction and tool Projection direction and tool orientation determined by orientation determined by drive surface (silver)drive surface (silver) 驱动曲面为单一曲面，而驱动曲面为单一曲面，而模型为多曲面模型模型为多曲面模型Single Single drive surface but multi-drive surface but multi-surface partsurface part狭槽的狭槽的5 5轴加工轴加工5
13、-5-Axis Machining of SlotsAxis Machining of Slots 3 3轴加工球刀清角时会留下圆角，必轴加工球刀清角时会留下圆角，必须手动加刀路清出直角须手动加刀路清出直角 Using 3-axis machining will leave Using 3-axis machining will leave a fillet in the corners. The corner a fillet in the corners. The corner must then be finished by handmust then be finished by ha
14、nd 5 5轴加工则可用平底刀清出利角，无轴加工则可用平底刀清出利角，无需在再后续电极清角需在再后续电极清角 Using 5-axis machining with an Using 5-axis machining with an end-mill leaves a sharp corner, end-mill leaves a sharp corner, needing minimal hand finishingneeding minimal hand finishing 不用后续电极清角就意味着节省时不用后续电极清角就意味着节省时间提高加工质量间提高加工质量 The reduction
15、 in hand finishing The reduction in hand finishing saves time and improves qualitysaves time and improves qualitySwarfSwarf加工加工Swarf MachiningSwarf Machining SwarfSwarf加工使用刀具侧刃切削加工使用刀具侧刃切削Swarf Machining cuts with Swarf Machining cuts with the side of the toolthe side of the tool 由于切削刀具是直刃，所以只由于切削刀具
16、是直刃，所以只能加工可展开的曲面（直纹面）能加工可展开的曲面（直纹面）It can only be used with It can only be used with developable surfaces as developable surfaces as cutter side is straightcutter side is straight 切削的深度可由下切步距和曲切削的深度可由下切步距和曲面宽度控制面宽度控制Depth of cut can Depth of cut can be controlled by a fixed be controlled by a fixed
17、stepover or fraction of stepover or fraction of surface widthsurface width用锥度刀做用锥度刀做SwarfSwarf加工加工Swarf machining with tapered toolsSwarf machining with tapered tools 允许使用更大的刀具允许使用更大的刀具Allows larger tools to Allows larger tools to be usedbe used 能够切除更多的余量能够切除更多的余量Removes more Removes more materialma
18、terial 使工件的装夹更灵活使工件的装夹更灵活Increases flexibility Increases flexibility possible in fixturespossible in fixtures线框线框SwarfSwarf加工加工Swarf machining from wireframeSwarf machining from wireframe在曲面不能真正展开在曲面不能真正展开( (非非直纹面）的时候特别适用直纹面）的时候特别适用Suitable where surfaces are Suitable where surfaces are not truly de
19、velopablenot truly developable在曲面内部结构很差时特在曲面内部结构很差时特别适用别适用Suitable where internal Suitable where internal surface structure is poorsurface structure is poor在曲面边缘加工不理想时在曲面边缘加工不理想时特别适用特别适用Suitable where edge Suitable where edge matching is not perfectmatching is not perfect5 5轴钻孔轴钻孔5-Axis Drilling Pow
20、erMILLPowerMILL能够自动识别其能够自动识别其他他CADCAD系统产生的孔特征，系统产生的孔特征，并自动产生五轴钻孔刀路并自动产生五轴钻孔刀路 对于对于HeidenhainHeidenhain等有等有working planeworking plane功能的五轴功能的五轴controllercontroller，DuctpostDuctpost以钻以钻孔循环输出；对于孔循环输出；对于AndronAndron等不支持等不支持working planeworking plane的的五轴五轴controllercontroller，DuctpostDuctpost以普通线性插补以普通线性
21、插补G01G01输出。输出。PowerMILLPowerMILL针对发动机等的弯形管件有从粗加工到针对发动机等的弯形管件有从粗加工到精加工的一套加工方案精加工的一套加工方案自动防护选项自动防护选项Auto-avoid optionAuto-avoid option 自动调整刀路避免碰撞自动调整刀路避免碰撞Automatically adjusts Automatically adjusts toolpath to avoid collisiontoolpath to avoid collision 在公差范围内自动调整在公差范围内自动调整刀轴方向避免干涉刀轴方向避免干涉Changes tool
22、 axis Changes tool axis automatically to avoid automatically to avoid obstruction by tolerance obstruction by tolerance specifiedspecifiedHuronKX8-Five controlled by Siemens 840D Feedrate: 7500mm/min Standard Toleranced DataActual Machining time: 82 minutesRedistributed Points (0.25mm Max)Actual Mac
23、hining time: 50 minutes39% Machine time saved by utilising Point Redistribution. 五轴机床仿真五轴机床仿真 1.1.五轴刀具路径完全自动防过切和自动刀头碰撞检查。该特性跟五轴刀具路径完全自动防过切和自动刀头碰撞检查。该特性跟三轴加工一样良好。三轴加工一样良好。 2.2.建立实际五轴机床模型，有效避免机台碰撞。五轴加工跟三轴建立实际五轴机床模型，有效避免机台碰撞。五轴加工跟三轴加工最大的不同，就是前者由于工作台或刀头的摆动和旋转，加加工最大的不同，就是前者由于工作台或刀头的摆动和旋转，加工过程中容易发生主轴或刀头刀具
24、跟工件、夹具、工作台碰撞。工过程中容易发生主轴或刀头刀具跟工件、夹具、工作台碰撞。区别于三轴加工只需注意到的刀头跟工件的碰撞，我们将其称为区别于三轴加工只需注意到的刀头跟工件的碰撞，我们将其称为机台碰撞。这样通过仿真无碰撞的程序，就可以放心的在五轴机机台碰撞。这样通过仿真无碰撞的程序，就可以放心的在五轴机床上运行。床上运行。DMU160POPS650Mikron UCP710仿真与验证仿真与验证 PowerMILLPowerMILL的仿真可选项的仿真可选项现扩展到包含了验证功能；现扩展到包含了验证功能； Simulation option in PowerMILL Simulation opt
25、ion in PowerMILL has now been extended to has now been extended to include verificationinclude verification 程序上机床之前，在计算程序上机床之前，在计算机上进行检查；机上进行检查； Allows programs to be checked Allows programs to be checked on the computer before being on the computer before being sent to the machinesent to the machin
26、e 计算速度快计算速度快 3+23+2编程方便、快捷编程方便、快捷 刀轴控制灵活多样，刀轴控制灵活多样， 3 3轴、轴、3+23+2轴、五轴联动可在一个程轴、五轴联动可在一个程序并存序并存 保障整个加工过程安全、稳定保障整个加工过程安全、稳定Click to edit Master title style Click to edit Master text stylesSecond level Third level Fourth level Fifth level46Delcam plc | Small Heath Business Park | Birmingham | B10 0HJ | UK
