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The generating grinding method has the characteristics of high machining accuracy and high efficiency. Therefore, it is widely used in the finishing process of the face gear tooth surface. The physical performance of the grinding process is an important factor that influences the machining accuracy of the face gear tooth surface. Therefore, to improve the manufacturing accuracy of the face gear, it is necessary to accurately simulate the grinding process of the face gear. Owing to the influence of the complex spatial geometric characteristics of the face gear tooth surface and the grinding wheel, establishing a surface residual modeling method for the face gear is a key challenge in simulating the generating grinding process. To address the aforementioned issues, this study proposes a normal cutting depth iterative method to calculate the grinding residual in the face gear generating grinding process. This method considers the complex 3D spatial characteristics of the face gear tooth surface and establishes the spatial residual model of each node of the face gear surface in the process of generating grinding. Compared with other residual algorithms based on 2D truncation or Boolean operation of face gears, this algorithm has higher computational accuracy and efficiency. Thus, it lays the foundation for accurately establishing the complex spatial microscopic surface topography in the face gear generating grinding process. [ABSTRACT FROM AUTHOR]

The five-axis flank milling process of sculptured surfaces is an intricate process involving time-varying and nonlinear characteristics under the multiphysics coupling effect. The milling force during the process is an important factor that influences the machining accuracy of sculptured surfaces. Face gears, as parts with sculptured surfaces, are widely employed in the aerospace and machinery manufacturing industries. To realize the high-precision manufacturing of face gears with a universal milling machine, this study proposes a five-axis flank milling method for face gears. In addition, based on the tangent plane approximation algorithm and the Receptance Coupling Substructure Analysis (RCSA) method, the milling force and the tool tip vibration during the face gear machining process are investigated. Finally, a five-axis flank milling force model and a face gear surface machining error model are established considering the interaction between the milling force and the process system. [ABSTRACT FROM AUTHOR]

This study aimed to develop software for multi-axis electrical discharge machining (EDM) computer numerical control (CNC) systems using open CNC technology and soft CNC technology and to then apply the software to the machining of rimmed turbine blisks. Through the analysis of functional requirements, this study established the hierarchy structure of the software. On the basis of this structure, three main modules and their communications were established with Linux and RT-Linux as the development platforms. The software architecture was also constructed. Through the construction of the modules and communications and the realization of the functions, the multi-axis EDM CNC system software was developed and installed into a five-axis EDM CNC machine to realize the machining of rimmed turbine blisks. Machining results show that the architecture of the software is correct, harmonious, and reasonable. The software is also stable and reliable and features strong real-time capability and accurate movement control. [ABSTRACT FROM AUTHOR]