桶形刀具對於複雜曲面加工效率與品質提升的實證分析

隨著智慧製造的不斷發展，對於五軸加工機與加工效率優化受到高度關注，且針對桶形刀具的應用需要更深入的研究。在本文中以HyperMill 軟體針對具有複雜曲面的工件規劃刀具路徑同時設計適合的桶形刀具，並以永進NFP500A五軸工具機台進行實機驗證。在進行實切複雜曲面以前，將透過HyperMill CAD設定切削參數包括轉速、進給、切削深度、切削寬度、加工工法等，探討出能夠實際在五軸工具機上切削的刀具，並生成最佳化節能的刀具路徑，藉由對比使用三軸工法的球刀及五軸工法的酒桶形銑刀實際切削的成果。本文中針對兩種不同刀具不同工法所得出的加工時間、加工面表面粗糙度等進行優劣的比較，並得出針對此複雜曲面所選擇的最佳化刀具外型。結果顯示，在理論表面粗糙度同樣限制在0.4167um時，半徑為3mm的球刀所能輸出的步距為0.1mm，而曲率半徑為150mm的圓錐形桶形刀所能輸出的步距則為0.7mm，桶形刀的可執行步距為球刀的七倍，且半徑為3mm的球刀在同樣具有複雜曲面工件的加工時間為9分38秒，而曲率半徑為150mm的圓錐形桶形刀的加工時間則為1分40秒，加工效率提升了261%。

With the continuous development of smart manufacturing, five-axis processing machines and processing efficiency optimization have received great attention, and the application of barrel-shaped tools requires more in-depth research. In this article, HyperMill software is used to plan tool paths and suitable barrel-shaped tools for workpieces with complex curved surfaces, and the YCM NFP500A five-axis tool machine is used for actual machine verification. Before cutting complex curved surfaces, the cutting parameters including speed, feed, cutting depth, cutting width, processing method, etc. will be set through HyperMill CAD to explore the cutting tools that can actually be cut on a five-axis machine tool and generate the best Energy-saving tool path, by comparing the actual cutting results of a ball cutter using a three-axis method and a barrel-shaped milling cutter using a five-axis method. This article compares the advantages and disadvantages of the processing time and surface roughness of the machined surface obtained by two different cutting tools and different working methods, and obtains the optimal tool appearance selected for this complex curved surface. The results show that when the surface roughness is also limited to 0.4167um, a ball cutter with a radius of 3mm can output a step of 0.1mm, while a conical barrel cutter with a curvature radius of 150mm can output a step of 0.7 mm, the executable step distance of the barrel cutter is seven times that of the ball cutter, and the processing time of the ball cutter with a radius of 3mm on the workpiece with the same complex curved surface is 9 minutes and 38 seconds, while the conical barrel cutter with a curvature radius of 150mm takes The processing time is 1 minute and 40 seconds, and the processing efficiency is increased by 261%.