五轴联动小型数控铣床结构设计与加工仿真 摘要 随着生物医疗器械、微电子、国防及航空航天等对微小型复杂零件需求的增加，采用传统机床难以经济、高效地满足微小零件的加工需求，需要多轴联动的小型数控机床来满足这些微小复杂零件的加工需求。本设计在对目前微小型多轴联动机床调研分析基础上，设计了一款具有B/C回转轴的五轴联动数控铣床，基于有限元分析软件分析了结构特性，并开展了数控加工仿真。设计的主要内容如下： （1）通过对现有多轴联动数控机床结构布局方案的对比分析，以小型化和轻量化为目标，设计了一款具有B/C回转轴的小型五轴联动数控铣床，可实现140×140×130mm零件加工。基于SoildWorks建立了该小型数控铣床的三维数字化模型，给出了机床传动系统设计计算过程，包括滚珠丝杠、直线导轨、伺服电机、铣削用电主轴、力矩电机及数控转台等的选型计算。 （2）基于ANSYS有限元软件，对该五轴联动小型数控铣床的整机结构进行了静力学分析，从结构重量、变形、固有频率与振型等方面，对机床的初步结构方案进行设计分析，通过分析比较最终确定出该机床的基座和立柱的筋板合理布局。 （3）基于UG/NX10.0建立了叶轮加工模型，通过设定加工条件生成叶轮的加工工序进行刀轨数据；基于UG/Post Builder10.0后处理构造器，开发了该小型五轴联动数控铣床的后处理程序，通过设定机床和刀轨参数，并将生成的叶轮加工刀轨数据转换成NC程序。 （4）基于VERICUT软件建立了该五轴联动数控铣床的加工仿真系统，可以实现该机床虚拟数控加工仿真分析。以叶轮加工为例，将生成好的NC加工程序输入到该仿真系统，实现了叶轮仿真加工，确保加工过程无过切和欠切，保证NC程序正确的同时，验证了后处理器的可靠性。 关键词：五轴联动数控铣床，小型机床，有限元分析，后处理器，数控加工仿真 Structural Desig
n a
nd Machi
ni
ng Practice of Five-axis CNC Milli
ng Machi
ne ABSTRACT With the i
ncreasi
ng dema
nd for micro a
nd small complex parts for biological medical devices, microelectro
nics,
natio
nal defe
nse a
nd aerospace, it is difficult to meet the processi
ng
needs eco
nomically a
nd efficie
ntly by usi
ng traditio
nal machi
ne tools. Based o
n the i
nvestigatio
n a
nd a
nalysis of micro a
nd small multi-axis li
nkage machi
ne tools i
n the curre
nt research field, this thesis desig
ns a five-axis CNC milli
ng machi
ne with B/C rotary axis, a
nalyzes its structural characteristics. The mai
n co
nte
nts of the graduatio
n project are as follows: (1) Through the comparative a
nalysis of the existi
ng multi-axis CNC machi
ne tool structure layout, aimi
ng at mi
niaturizatio
n a
nd lightweight, a small five-axis CNC milli
ng machi
ne structure with B/C rotary axis is desig
ned, which ca
n realize the processi
ng of 140×140 ×130mm parts.Based o
n SoildWorks, the 3d digital model of the small CNC milli
ng machi
ne is established, a
nd the desig
n a
nd calculatio
n process of the tra
nsmissio
n system of the machi
ne is give
n, i
ncludi
ng the selectio
n a
nd calculatio
n of the ball screw, rolli
ng guide rail, servo motor, spi
ndle, torque motor a
nd CNC tur
ntable, etc. (2) Based o
n ANSYS, the static a
nd modal a
nalysis of the importa
nt parts of the machi
ne tool are carried out. Accordi
ng to the a
nalysis results, the origi
nal structure is modified a
nd optimized from three aspects of weight, deformatio
n a
nd modal a
nalysis. (3) The impeller machi
ni
ng model was established based o
n UG/NX10.0, a
nd the machi
ni
ng process of impeller was ge
nerated a
nd processed by setti
ng machi
ni
ng co
nditio
ns.Based o
n UG/Post Builder10.0 postprocessi
ng co
nstructor, the postprocessi
ng program of the five-axis CNC milli
ng machi
ne was developed, the parameters of the machi
ne tool a
nd the tool rail were set, a
nd the ge
nerated data of the impeller machi
ni
ng tool rail was co
nverted i
nto NC program. (4) Build a five-axis machi
ni
ng simulatio
n system based o
n VERICUT software. The simplified processi
ng a
nd ki
nematic a
nalysis of the desig
ned machi
ne tool model were carried out, a
nd fi
nally the NC program was used to simulate the machi
ni
ng of the impeller to e
nsure that the machi
ni
ng process was free from over-cutti
ng a
nd u
nder-cutti
ng. The machi
ned surface is a
nalyzed to e
nsure the correct operatio
n of NC program. KEY WORDS: Five-axis CNC milli
ng machi
ne, mi
niaturized machi
ne tool, fi
nite eleme
nt a
nalysis, post-processor, CNC machi
ni
ng simulatio
n 目录 第1章绪论1 1.1研究背景及意义1 1.2五轴机床的发展现状1 1.3后处理技术的研究现状5 1.4设计（）整体思路5 第2章小型五轴数控机铣床的结构设计7 2.1机床结构布局方案确定7 2.2机床的基本结构设计8 2.3机床驱动传动部件的选型计算10 2.3.1.滚珠丝杠选型计算10 2.3.2.电机选型计算14 2.3.3直线滑轨选型计算19 2.3.4其余零部件22 2.4本章小结22 第3章五轴机床结构方案分析23 3.1有限元软件简介23 3.2方案对比的流程23 3.3模型的简化24 3.4分析准备25 3.4.1.模型导入25 3.4.2.材料的选择及网格的划分25 3.4.3.边界条件的确定26 3.5方案分析结果对比27 3.5.1底座方案分析28 3.5.2立柱的方案分析32 3.6经济性分析33 3.7本章小结34 第4章五轴机床加工仿真35 4.1毛坯建立35 4.2基于UG的数控编程和后置处理35 4.2.1 UG CAM下的叶轮加工模块35 4.2.2刀轨数据生成36 4.3基于UG/Post Builder的后处理程序构建39 4.3.1机床参数设置39 4.3.3基于后置处理器的刀轨代码生成43 4.4基于VERICUT的加工仿真43 4.4.1机床模型组建43 4.4.2加工刀具设置44 4.4.3干涉及行程检查设置45 4.4.4建立仿真加工环境并虚拟加工46 4.5本章小结47 第5章总结与展望49 5.1全文总结49 5.2展望49 参考文献51 致谢53 第1章绪论 1.1研究背景及意义 五轴联动数控机床是一种科技含量高、加工精度高的专门用于加工复杂空间曲面的机床。五轴联动机床系统对一个国家的航天、航空、军事、精密器械、高精医疗设备等行业，有着非同传统机床的巨大影响力。 五轴联动数控机床是指在一台机床上至少有5个坐标轴，通常为3个直线运动坐标（X，Y，Z）和两个旋转运动坐标（A，B，C）。五轴机床各个坐标轴协调运动，共同完成空间曲面的加工。根据机械有关知识，重新夹装被加工件，对夹具要求很高。如果加工零件多次装夹，需要重新寻找基准坐标，这样做会影响后续加工精度，带来不可避免的误差。用五轴联动机床一次装夹定位后可以在有效行程内完成多个面位的加工，对于少于五面位的零件能一次装夹完成加工。所以说，五轴联动数控机床也是目前用来解决空间曲线复杂的零件加工[2]。人们在设计、制造复杂曲面遇到无法解决的难题,就会利用五轴加工技术解决。比如叶轮、叶片等复杂的零部件。 随着数控技术的发展，一方面，在生物医学，航空航天，计算机技术等多个重要领域对于小型复杂零件的需求越来越多，对零件的加工精度要求也日