Double-row Slot Plunge Milling Processing Method for Integral Impellers

A double-row slot plunge milling processing method for integral impellers, comprising the following steps of:

• step 1:
• obtaining CAD model data of an integral impeller;
• step 2:
• obtaining width data of a bottom portion of a cross-section of a flow channel;
• analyzing the CAD model, and obtaining discrete data of width change of the bottom portion of the cross-section of the flow channel from outlet to inlet by software measurement;
• step 3:
• determining a direction of plunge milling cutter arrangement;
• according to a width of the bottom portion of the cross-section of the flow channel of the impeller, selecting a cutter with a diameter smaller than a minimum value of the width of the bottom portion of the cross-section of the flow channel of the impeller, and planning a single-row plunge milling cutter path along a middle line of the flow channel by using a CAM software platform or a high-level computer language programming method;
• through cutting simulation, judging whether cutter bumping is not generated in cutter arrangement from the inlet to outlet or from the outlet to inlet, and selecting a direction without the cutter bumping as a direction of the plunge milling cutter arrangement;
• step 4:
• according to the determined direction of plunge milling cutter arrangement in step 3, segmenting the flow channel of the impeller into a plurality of segments along a direction of the inlet and outlet, and selecting a size of the cutter according to the width of the bottom portion of the cross-section of the flow channel of each segment;
• if the cutter is arranged from the outlet to inlet of the flow channel, using the outlet end as a starting point of first segment, and selecting diameter of the cutter based on a principle that the diameter is greater than 50% of the width of the bottom portion of the cross-section of the flow channel at the starting point of the segment and less than 80% of the width of the bottom portion of the cross-section of the flow channel at the starting point of the segment;
• according to the selected diameter of the cutter, using a position where the width of the bottom portion of the cross-section of the flow channel equal to 1.02 to 1.05 times the diameter of the cutter as an end point of the first segment, and processing each segment by only one cutter;
• using the end point of the first segment as a starting point of a second segment, and repeating the steps above until reaching the inlet end of the flow channel;
• if the cutter is arranged from the inlet to outlet of the flow channel, using the inlet end as the starting point of the first segment of the flow channel, and selecting the diameter of the cutter based on a principle that the diameter is less than 98% of the width of the bottom portion of the cross-section of the flow channel at the starting point of the segment and greater than 50% of the width of the bottom portion of the cross-section of the flow channel at the starting point of the segment;
• according to the selected diameter of the cutter, using a position where the width of the bottom portion of the cross-section of the flow channel equal to 1.4 to 1.6 times the diameter of the cutter as the end point of the first segment, and processing each segment by only one cutter;
• using the end point of the first segment as the starting point of the second segment, and repeating the steps above until reaching the outlet end of the flow channel;
• step 5:
• projecting a double-row plunge milling cutter path along two side blades of the flow channel;
• according to each segmented flow channel and the size of the cutter determined in step 4, projecting the double-row plunge milling cutter path along the direction of the inlet and outlet of the flow channel by the CAM software platform or the high-level computer language programming method;
• performing a cutter arrangement sequence of each segment in strict accordance with the cutter arrangement sequence in step 3, only the cutter arrangement sequence of the last segment being reversed;
• in each segment, determining a priority sequence of the cutter paths of left row and right row according to plunge milling depth cutting simulation, processing deep plunge milling row first, then processing shallow plunge milling row;
• and
• step 6:
• processing the arranged cutter paths into a numerical control processing program, and driving a machine tool to finish rough processing of the flow channel of the impeller.