A radius compensation method of barrel tool based on macro variables in five-axis flank machining of sculptured surfaces

Abstract

Barrel tool radius compensation is very important to improve the five-axis CNC machining precision and efficiency of sculptured surfaces. By combining macro variables and math function of CNC controller, a radius compensation method of barrel tool based on macro variables in five-axis flank machining of sculptured surfaces was presented. The basic principle of barrel tool radius compensation in five-axis flank machining was firstly investigated. For a specific five-axis CNC machine tool with dual rotary tables, a relationship equation between compensated cutter location (CL) data and machine control (MC) data could be derived. A post-processor with the function of five-axis barrel tool radius compensation was then developed by using the C++ language, which could generate the NC programme with macro variables of barrel tool radius compensation. Finally, the NC programme was obtained automatically by the developed post-processor for the aero-engine blade surface machining. The machining process was simulated on the software VERICUT, and machining experiments were also conducted on the five-axis machine tool. Both the simulation and experimental results showed that the proposed method could perform the function of barrel tool radius compensation in the NC programme for five-axis flank machining.

Keywords:

• barrel tool
• tool radius compensation
• five-axis
• flank machining
• sculptured surfaces
• CNC machining

Additional information

Funding

This work was supported by the National Science and Technology Major Project of China [grant number 2018ZX04005001], National Natural Science Foundation of China [grant number 51505264 and 51875028], National Key Research and Development Program of China [grant number 2018YFB2001400] and Shandong Provincial Natural Science Foundation, China [grant number ZR2017MEE060 and ZR2017MEE050].