鲁达 1.概论
双摆头五轴联动数控加工中心C角度超程回摆问题是长期困扰五轴编程人员的一个难题。过去，很多编程人员过分依赖后处理的功能来解决此类问题。然而五轴编程是一个复杂的过程，如果编程人员在编程时对切削过程不进行相应处理，后处理是无法将五轴摆角处理成为我们所要求数值的。本文对在五轴联动数控加工中心C角超程回摆问题进行了探讨，使编程员对其进行 分析、处理，基本解决了五轴编程时大部分问题，从而编制出理想的加工程序。
双摆头机床受机床结构限制C轴通常是±360°或±240°。不能像摇篮式五轴C轴可以做无限制360°连续转动（也有双摆头的机床C轴可以无限制旋转的，这样的机床比较贵）。
以C轴±240°机床为例：
图1
以前遇到类似的问题，通常是改变加工方法，如将侧刃铣削改为底刃铣削、将单个曲面分段加工等，但上述方法会降低零件的表面质量，增加使用刀具的长度，降低切削效率。为此， 解决C角超程问题，对于提高产品合格率及切削效率、降低公司设备采购成本有极大的意义。
以C轴行程±240°的机床为例C轴的范围是-240°~-180°~-90°~0°~90°~180°~240°,机床如果从-240°开始转到240°时的行程是480°明显大于工件加工一圈侧壁需要的360°理论上机床可以加工一圈侧壁不超程。
2. C角超程回摆问题的分析
首先，我们来分析五轴机床超程回摆问题是怎么发生的(注：本文以刀具摆动，A角行程为±105° ，C角行程为±240°的机床为例)。对于圆锥面的加工，要想用数控铣加工不分段加工出一个完整的圆锥，C摆角必须能连续回转360°，由于C摆角的行程限制(±240°)，C轴的初始值必须在±180°以外。否则，会出现C轴超程回摆。
软件通常是从C0°开始加工，C0°~ C90°~ C180°~ C240°这时候机床超程刀具撤回，整圆还差120°才能加工完，机床C轴转到一个新的角度，从刚才撤回刀具的位置接着加工。在接刀位置会留下接刀痕，影响表面加工质量。
如果C轴的初始位置能从C-240°~C-120°之间开始，刀具路径经过C-120°~ C-90°~ C0°~ C90°~ C180°~ C240°就可以加工一圈不用撤刀，这样加工表面质量良好。
3. POWERMILL软件编程解决方案
问题分析出来了，我们看看怎么在POWERMILL中解决
在POWERMILL加工轴控制中选择行程方向，偏移角输入-180°然后计算程式，得到的NC代码如下：
0 BEGIN PGM 11 MM
1 M44
2 M45
3 ;PROGRAM DATE : 15/05/19 AT 21:54:34
4 ;OPTION FILE : 5BC-329
5 ;( ^ HARDFORT^ OUTPUT_WORKPLANE : POST )
6 ;
7 BLK FORM 0.1 Z X-220.0 Y-220.0 Z+0.0
8 BLK FORM 0.2 X+220.0 Y+220.0 Z+10.0
9 LBL 170
10 CYCL DEF 7.0 DATUM SHIFT
11 CYCL DEF 7.1 X0.000
12 CYCL DEF 7.2 Y0.000
13 CYCL DEF 7.3 Z0.000
14 PLANE RESET STAY
15 LBL 0
16 L M129
17 CYCL DEF 247 DATUM SETTING~
Q339=+1 ;DATUM NUMBER
18 TOOL CALL S18000
L M03
19 ;=========
20 ; TOOLPATH : 2
21 ; WORKPLANE : WORLD
22 ; OUTPUT WORKPLANE : POST
23 ; THICKNESS: 0.070 TOLERANCE:0.010
24 ;( TOOL_ID = D10 )
25 ;( TOOL_D =10.0 TOOL_R = 0.0 LENGTH 130.0
26 ;=========
27 CYCL DEF 32.0 TOLERANCE
28 CYCL DEF 32.1 T0.010
29 CYCL DEF 32.2 HSC-MODE:0 TA1
; SET MULTIAXIS ON
30 M44
31 M45
32 L M126
33 L M128 F3000
34 ;*** FIRST MOVE 5AX ***
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684 L X+203.4433 Y-8.3278 Z+3.6134
685 L X+203.4862 Y-8.8575 Z+3.6723
686 L X+203.5724 Y-9.3932 Z+3.7747
687 L X+203.7041 Y-9.9245 Z+3.9224
688 L X+203.8818 Y-10.4401 Z+4.1156
689 L X+204.1042 Y-10.9284 Z+4.3527
690 L X+204.3681 Y-11.3782 Z+4.6301
691 L X+204.6684 Y-11.7798 Z+4.9424
692 L X+204.9984 Y-12.1253 Z+5.2827
693 L X+205.3506 Y-12.4094 Z+5.6433
694 L X+205.7168 Y-12.6294 Z+6.016
695 L X+206.089 Y-12.7856 Z+6.3928
696 L X+206.4597 Y-12.8802 Z+6.7663
697 L X+206.8226 Y-12.9178 Z+7.1301
698 L X+34.0509 Y-7.1324 Z+180.0 F3000
699 ; END OF TOOLPATH
700 L M129
701 L Z-10.0 R0 F5000 M91
702 L B+0 C+0 R0 F5000 M91
703 L M09
704 CYCL DEF 32.0 TOLERANCE
705 CYCL DEF 32.1
706 ;
707 CALL LBL 170
708 L M129
709 L Z-10.0 R0 F5000 M91
710 M44
711 M45
712 L B+0 R0 F5000
713 L C+0 R0 F5000
714 L M127
715 L M05
716 L M09
717 M30
718 END PGM 11 MM
机床C轴从C177.9743°~0°~ C-181.9179°完整加工一圈不撤刀。
如果不处理程式C轴起始位置在机床240°时会有一个撤刀动作，NC代码如果：
464 L X+119.3318 Y-164.9459 C-234.1158
465 L X+117.6596 Y-166.143 C-234.6945
466 L X+115.9753 Y-167.323 Z+3.5946 C-235.2733
467 L X+114.2792 Y-168.486 Z+3.5947 C-235.8521
468 L X+112.5714 Y-169.6318 C-236.4309
469 L X+110.8521 Y-170.7603 C-237.0096
470 L X+109.1216 Y-171.8713 C-237.5884
471 L X+107.3798 Y-172.9648 C-238.1672
472 L X+105.6272 Y-174.0407 C-238.746
473 L X+103.8637 Y-175.0988 C-239.3248
474 L X+102.0897 Y-176.139 C-239.9035
475 L X+101.7923 Y-176.3094 C-240.0 B+45.0
476 ; START RETRACT AND RECONFIGURE
477 L X-21.951 Y+38.0202 Z+251.0829 F3000
478 L C+120.0
479 L X+95.6051 Y-165.5929 Z+15.9691
480 L X+101.7923 Y-176.3094 Z+3.5947 F2450
481 ; END RETRACT AND RECONFIGURE
482 L X+100.3052 Y-177.1613 C+119.5177 B+45.0 F3500
483 L X+98.5105 Y-178.1655 C+118.9389
484 L X+96.7058 Y-179.1515 C+118.3601
485 L X+94.8912 Y-180.1192 C+117.7813
486 L X+93.0669 Y-181.0685 C+117.2026
487 L X+91.2331 Y-181.9994 C+116.6238
488 L X+89.39 Y-182.9117 C+116.045
489 L X+87.5377 Y-183.8053 C+115.4662
490 L X+85.6766 Y-184.6802 C+114.8875
491 L X+83.8067 Y-185.5362 C+114.3087
492 L X+81.9282 Y-186.3733 C+113.7299
493 L X+80.0414 Y-187.1914 C+113.1511
494 L X+78.1464 Y-187.9904 C+112.5723
495 L X+76.2435 Y-188.7702 C+111.9936
496 L X+74.3327 Y-189.5307 C+111.4148
还有其它做法，需要后处理配后，我们后面再探讨。