Jia Jinjie, Song Wenyuan, Huang Mingcong, Zhang Ye, Yuan Xinman, Zhang Xicheng, Tang Dan, Zhang Tingyu, Xue Zhao, Jiang Yan
Chengdu Aircraft Industrial (Group) Co., Ltd, Chengdu, 610092, China.
School of Mechanical and Power Engineering, Henan Polytechnic University, Jiaozuo, 454150, China.
Sci Rep. 2025 Apr 1;15(1):11165. doi: 10.1038/s41598-025-95159-8.
Thread milling plays a critical role in the machining of aviation components. However, for parts with complex shapes and high precision requirements, traditional three-axis milling often results in significant errors, making it difficult to meet the stringent machining specifications. In this paper, an error control method based on a crossed axes strategy for five-axis thread milling is proposed. Firstly, the thread profile is constructed using both the axial cross-section and the normal section. The geometry of the thread mill is derived from the nominal profile on the axial cross-section. Then, the tool path is defined, where a new locus is introduced to control milling errors. Building upon this, the envelope theory is employed to establish an error model for the milling process, and the errors under different milling strategies are compared. Finally, the impact of the fixed angle on machining errors is analyzed, and experiments are conducted to compare the thread milling performance of three-axis and five-axis. The results demonstrate that as the fixed angle changes from 0 to 0.0282 radians, the angle error shifts from -0.796 to 0.808 degrees, and by selecting an optimal fixed angle in 5-axis milling, the error can be minimized, validating the superior machining accuracy and effectiveness of the proposed approach.
螺纹铣削在航空零部件加工中起着关键作用。然而，对于形状复杂且精度要求高的零件，传统的三轴铣削常常会导致显著误差，难以满足严格的加工规格。本文提出了一种基于五轴螺纹铣削交叉轴策略的误差控制方法。首先，利用轴向截面和法向截面构建螺纹轮廓。螺纹铣刀的几何形状由轴向截面的名义轮廓导出。然后，定义刀具路径，引入新的轨迹来控制铣削误差。在此基础上，运用包络理论建立铣削过程的误差模型，并比较不同铣削策略下的误差。最后，分析固定角度对加工误差的影响，并进行实验比较三轴和五轴的螺纹铣削性能。结果表明，随着固定角度从0变化到0.0282弧度，角度误差从-0.796度变化到0.808度，通过在五轴铣削中选择最佳固定角度，可以使误差最小化，验证了所提方法具有更高的加工精度和有效性。
