基于动力学仿真的砂轮修形机的研究与设计
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摘要
成型磨削是利用CNC技术一次磨削使工件达到最终加工工序的加工尺寸要求的一种现代加工方法,通常直接决定了工件的精度。因此成形砂轮修整就成了成形磨削的关键因素之一。本文研究的目的是研究和设计一种能解决用于复杂零件表面磨削的成型砂轮的加工问题的母线砂轮修型机床。
本文首先根据成型磨削中砂轮的实际使用要求,对砂轮修型机进行了功能规划和总体性能分析。重点分析了本机床的目标精度和总体结构,并对关键部件进行了选型设计和分析。
其次,砂轮修型机的主轴部件和进给部件是整个机床中最关键的两个部件,其结构性能直接影响了砂轮修整的精度,故本文在分析了主轴部件设计中的关键要素和几种常用的主轴结构的基础上对本机床的主轴部件的结构进行了设计;另外根据砂轮修整的尺寸范围对进给部件特别是刀杆组件进行了设计。
再次,利用大型通用有限元分析软件ANSYS作为分析工具,对主轴部件和刀杆组件进行有限元建模和机械性能分析,并根据分析结果对主轴部件和刀杆组件进行了结构优化设计。
最后,利用振动测试仪对砂轮修型机的主轴部件和刀杆组件的性能进行了测试,实验结果表明机床的整体性能达到了设计精度要求,证明了本设计中的方法和理论的实用性。
Forming grinding, which is a modern processing methods which the CNC technology is used to achieve the ultimate processing workpiece machining requirements of the size only in a time grinding , usually directly determines the accuracy of the workpiece. Therefore forming dresser became one of the key factors in forming grinding. The purpose of this paper is to study and design a machine for grinding the surface of complex parts
According to the actual use requirements of molding grinding wheel, designs of the function layout and analysis of the collectivity capability of the grinding wheel shaping machine are finished in this paper. As well as special analysis focused on improving this machine precision and overall structure .The object accuracy of the tool is analyzed emphatically, and the types and accuracy of key components are chosen.
Secondly, The machining accuracy of work piece is influenced by the accuracy of the spindle and feed component. Therefore, based on the analysis of the several key elements of the spindle design , the advantages and disadvantages of several common main axis structures. The main axis structure of the machine tool is designed, and the feed component structure in accordance with the size of molding grinding wheel is designed also.
Thirdly, by using ANSYS ,one of the large-scale general-purpose finite element analysis software, the finite element modelings are built and mechanical performance of the spindle parts and arbor components are analyzed. Then both of the structures are optimized according to the analysis results.
Finally, experiment of testing on the performance of main shaft and arbor component by using vibration testing instrument during the processing has been produced. The experimental results show that the overall performance of machine tools meet the design accuracy requirements . and also prove that the design methods is practical
本文首先根据成型磨削中砂轮的实际使用要求,对砂轮修型机进行了功能规划和总体性能分析。重点分析了本机床的目标精度和总体结构,并对关键部件进行了选型设计和分析。
其次,砂轮修型机的主轴部件和进给部件是整个机床中最关键的两个部件,其结构性能直接影响了砂轮修整的精度,故本文在分析了主轴部件设计中的关键要素和几种常用的主轴结构的基础上对本机床的主轴部件的结构进行了设计;另外根据砂轮修整的尺寸范围对进给部件特别是刀杆组件进行了设计。
再次,利用大型通用有限元分析软件ANSYS作为分析工具,对主轴部件和刀杆组件进行有限元建模和机械性能分析,并根据分析结果对主轴部件和刀杆组件进行了结构优化设计。
最后,利用振动测试仪对砂轮修型机的主轴部件和刀杆组件的性能进行了测试,实验结果表明机床的整体性能达到了设计精度要求,证明了本设计中的方法和理论的实用性。
Forming grinding, which is a modern processing methods which the CNC technology is used to achieve the ultimate processing workpiece machining requirements of the size only in a time grinding , usually directly determines the accuracy of the workpiece. Therefore forming dresser became one of the key factors in forming grinding. The purpose of this paper is to study and design a machine for grinding the surface of complex parts
According to the actual use requirements of molding grinding wheel, designs of the function layout and analysis of the collectivity capability of the grinding wheel shaping machine are finished in this paper. As well as special analysis focused on improving this machine precision and overall structure .The object accuracy of the tool is analyzed emphatically, and the types and accuracy of key components are chosen.
Secondly, The machining accuracy of work piece is influenced by the accuracy of the spindle and feed component. Therefore, based on the analysis of the several key elements of the spindle design , the advantages and disadvantages of several common main axis structures. The main axis structure of the machine tool is designed, and the feed component structure in accordance with the size of molding grinding wheel is designed also.
Thirdly, by using ANSYS ,one of the large-scale general-purpose finite element analysis software, the finite element modelings are built and mechanical performance of the spindle parts and arbor components are analyzed. Then both of the structures are optimized according to the analysis results.
Finally, experiment of testing on the performance of main shaft and arbor component by using vibration testing instrument during the processing has been produced. The experimental results show that the overall performance of machine tools meet the design accuracy requirements . and also prove that the design methods is practical
引文
[1]汤道祥.砂轮修整器的选择与应用.磨床与磨削,1995(6):58-60
[2]PHILLI BEX,Grace Zhang.超硬磨料磨轮的激光修整[J].现代制造工程,2002(6):32-34
[3]蔡光起,冯宝富,赵恒华.磨削技术的最新进展.世界制造技术与装备市,2003(1):16-19
[4]邓中明,徐太荣.成形磨齿新型砂轮修整器的应用研究[J].机械制造,1999(12):30-31
[5]李治平.成型砂轮修整方法[J].工具技术,1990.No.7:8-9
[6]张秋菊,龚光容.修整成形砂轮的系统[J].制造技术与机床,1996(9):9-11
[7]李礼夫.三坐标数控磨轮修整器的无累积误差插补控制方法[J].机床与液压,1999(3):28-29
[8]李礼夫,刘丰林,邓兴奕.成型磨轮三坐标数控修整的优化方法[J].金刚石与磨料磨具工程,1999.6(114):21-24
[9]张德泉,李真.数字控制成形磨削技术的研究[J].制造技术与机床,1998(5):34-35
[10]张秋菊,龚光容.修整成形砂轮的系统[J].制造技术与机床,1996(9):9-11
[11]谢铁,张琦.从4520C(CNC型)看中小型无心磨床发展方向.磨床与磨削,1999(1):25-30
[12]焦文蔚,80年代国外无心磨床水平和发展.磨床与磨削,1993(2):31-33
[13]李浙昆,樊瑜瑾.砂轮磨粒尺寸及形状对磨削加工的影响.磨床与磨削,1999(1):37-39
[14]王清明,超精密车床几何误差分析与补偿技术研究.哈尔滨工业大学博士学位论文.1999
[15]戴一帆,李圣怡.超精密加工精度分析.中国机械工程,1999,10(2):203-204
[16]Xichun Luo,Kai Cheng,Dave Webb,Frank Wardle.Design of Ultraprecision Uachine Tools with Applications to Manufacture of Miniature and Microcomponents.Journal of Materials Processing Technology.2005,9412:1-14
[17]D.J.Stephenson,D.Veselovac,S.Manley,J.Corbett.Ultra-precision Grinding of Hard Steels,Precision Eng.2001(15):336- 345.
[18]Teltz R,Elbestawi M A,et al.Knowledge-based Control in Turing.ASME J.OfDSMC,1993
[19]http://www.htpm.com/
[20]http://www.remymc,com/
[21]Czajkowski Stephen,Eidelberg Boaz,Heinemann Gerhard,Stollberger Chris.Linear Motors:The Future of High-performance Machine Tools.American Machinist[AMMACH],1996
[22]http://www.yaskawa,com.cn/
[23]张新华.机床主轴组件的计算及精度评定[J].机械研究与应用,1999,(03):26-28
[24]刘阳,朱春霞,黄亚力,蔡光起.SSCK40的数控机床防护罩设计.东北大学学报,2007,(03):397-400
[25]普罗尼柯夫AC主编.金属切削机床,贾亚洲译.北京:北京科学技术出版社,1990
[26]姚伟明.减少主轴组件刚度损失的有效措施[J].煤矿机械,2000,(05):44-45
[27]孙振均.金属切削机床构造与设计.国防工业出版社,北京,1985,10
[28]《金属切削机床》编写组,金属切削机床设计,上海科学技术出版社,上海,1984,02
[29]张济生.主轴部件最佳支承跨距的精确计算[J].重庆大学学报,1995(10)36-37
[30]孔令页.新型数控成形砂轮修整器的设计及磨削性能研究.广东工业大学学位论文,2006
[31]Z.Q.Zhang,Q.S.Yan,S.B.Chen,Z.D.Zheng,lnfluence of Dresser setting and assembling errors on shape precision of form wheel[j],Key Engineering Materials,Vol,259-260(2004)pp63-67.
[32]李华.钻头球齿有限元法受力分析研究.吉林大学硕士学位论文.吉林:吉林大学,2001,4-5
[33]徐芝纶.弹性力学简明教程.北京:高等教育出版社,2002,6-7
[34]王勖成,邵敏.有限单元法基本原理和数值方法.北京:清华大学出版社1997,22-26
[35]龙驭球.有限元法概论.北京:高等教育出版社,1991,4-12
[36]C.S.德赛,J.F.阿尔贝.有限元素法引论.北京:科学出版社,1978,68-245
[37]汪家才.弹性和塑性理论及有限单元法.北京:冶金工业出版社,1983,4-5
[38]傅永华.有限元分析基础.武汉:武汉大学出版社,2003,9-10
[39]蔡四维,蔡敏.有限元素法-它的内容方法和实质.北京:科学出版社,1980,9-10
[40]刘国庆,杨庆东.ANSYS工程应用教程(机械篇).北京:中国铁道出版社,2003,1-2
[41]陆新征.ANSYS入门及学习方法.北京:清华大学出版社,2004,1-2
[42]祝效华,余志样等,ANSYS高级工程有限元分析范例精选[M].北京:机械工业出版社,2004
[43]田冠为.磨床砂轮修整器结构的有限元分析及优化的研究.东南大学硕士学位论文..江苏:南京,2003,12
[44]Bollinger J G,Geiger G.Analysis of the Static and Dynamic Behavior of Lathe Spindles.Int.J.Mach.Tool Des.Res.1964,3:193-09,
[45]StoutK.I,Barrans S M.The Design of Aerostatic Bearings for Application toNanometer Resolution Manufacturing Machine System.Tribology International.2000,(33):803-809
[46]彭文生,黄华梁等.机械设计.武汉,华中理工大学出版社,1996,126-127
[47]Sedighi.M,Mohammadi.M.On The Static and Dynamic Analysis of a SmallSatellite (MESBAH).Acta Astronautica.2003,52(9):1007-1012
[48]樊振将.机械振动及其计算机辅助测试[M],北京:机械工业出版社,1996,32-37
[2]PHILLI BEX,Grace Zhang.超硬磨料磨轮的激光修整[J].现代制造工程,2002(6):32-34
[3]蔡光起,冯宝富,赵恒华.磨削技术的最新进展.世界制造技术与装备市,2003(1):16-19
[4]邓中明,徐太荣.成形磨齿新型砂轮修整器的应用研究[J].机械制造,1999(12):30-31
[5]李治平.成型砂轮修整方法[J].工具技术,1990.No.7:8-9
[6]张秋菊,龚光容.修整成形砂轮的系统[J].制造技术与机床,1996(9):9-11
[7]李礼夫.三坐标数控磨轮修整器的无累积误差插补控制方法[J].机床与液压,1999(3):28-29
[8]李礼夫,刘丰林,邓兴奕.成型磨轮三坐标数控修整的优化方法[J].金刚石与磨料磨具工程,1999.6(114):21-24
[9]张德泉,李真.数字控制成形磨削技术的研究[J].制造技术与机床,1998(5):34-35
[10]张秋菊,龚光容.修整成形砂轮的系统[J].制造技术与机床,1996(9):9-11
[11]谢铁,张琦.从4520C(CNC型)看中小型无心磨床发展方向.磨床与磨削,1999(1):25-30
[12]焦文蔚,80年代国外无心磨床水平和发展.磨床与磨削,1993(2):31-33
[13]李浙昆,樊瑜瑾.砂轮磨粒尺寸及形状对磨削加工的影响.磨床与磨削,1999(1):37-39
[14]王清明,超精密车床几何误差分析与补偿技术研究.哈尔滨工业大学博士学位论文.1999
[15]戴一帆,李圣怡.超精密加工精度分析.中国机械工程,1999,10(2):203-204
[16]Xichun Luo,Kai Cheng,Dave Webb,Frank Wardle.Design of Ultraprecision Uachine Tools with Applications to Manufacture of Miniature and Microcomponents.Journal of Materials Processing Technology.2005,9412:1-14
[17]D.J.Stephenson,D.Veselovac,S.Manley,J.Corbett.Ultra-precision Grinding of Hard Steels,Precision Eng.2001(15):336- 345.
[18]Teltz R,Elbestawi M A,et al.Knowledge-based Control in Turing.ASME J.OfDSMC,1993
[19]http://www.htpm.com/
[20]http://www.remymc,com/
[21]Czajkowski Stephen,Eidelberg Boaz,Heinemann Gerhard,Stollberger Chris.Linear Motors:The Future of High-performance Machine Tools.American Machinist[AMMACH],1996
[22]http://www.yaskawa,com.cn/
[23]张新华.机床主轴组件的计算及精度评定[J].机械研究与应用,1999,(03):26-28
[24]刘阳,朱春霞,黄亚力,蔡光起.SSCK40的数控机床防护罩设计.东北大学学报,2007,(03):397-400
[25]普罗尼柯夫AC主编.金属切削机床,贾亚洲译.北京:北京科学技术出版社,1990
[26]姚伟明.减少主轴组件刚度损失的有效措施[J].煤矿机械,2000,(05):44-45
[27]孙振均.金属切削机床构造与设计.国防工业出版社,北京,1985,10
[28]《金属切削机床》编写组,金属切削机床设计,上海科学技术出版社,上海,1984,02
[29]张济生.主轴部件最佳支承跨距的精确计算[J].重庆大学学报,1995(10)36-37
[30]孔令页.新型数控成形砂轮修整器的设计及磨削性能研究.广东工业大学学位论文,2006
[31]Z.Q.Zhang,Q.S.Yan,S.B.Chen,Z.D.Zheng,lnfluence of Dresser setting and assembling errors on shape precision of form wheel[j],Key Engineering Materials,Vol,259-260(2004)pp63-67.
[32]李华.钻头球齿有限元法受力分析研究.吉林大学硕士学位论文.吉林:吉林大学,2001,4-5
[33]徐芝纶.弹性力学简明教程.北京:高等教育出版社,2002,6-7
[34]王勖成,邵敏.有限单元法基本原理和数值方法.北京:清华大学出版社1997,22-26
[35]龙驭球.有限元法概论.北京:高等教育出版社,1991,4-12
[36]C.S.德赛,J.F.阿尔贝.有限元素法引论.北京:科学出版社,1978,68-245
[37]汪家才.弹性和塑性理论及有限单元法.北京:冶金工业出版社,1983,4-5
[38]傅永华.有限元分析基础.武汉:武汉大学出版社,2003,9-10
[39]蔡四维,蔡敏.有限元素法-它的内容方法和实质.北京:科学出版社,1980,9-10
[40]刘国庆,杨庆东.ANSYS工程应用教程(机械篇).北京:中国铁道出版社,2003,1-2
[41]陆新征.ANSYS入门及学习方法.北京:清华大学出版社,2004,1-2
[42]祝效华,余志样等,ANSYS高级工程有限元分析范例精选[M].北京:机械工业出版社,2004
[43]田冠为.磨床砂轮修整器结构的有限元分析及优化的研究.东南大学硕士学位论文..江苏:南京,2003,12
[44]Bollinger J G,Geiger G.Analysis of the Static and Dynamic Behavior of Lathe Spindles.Int.J.Mach.Tool Des.Res.1964,3:193-09,
[45]StoutK.I,Barrans S M.The Design of Aerostatic Bearings for Application toNanometer Resolution Manufacturing Machine System.Tribology International.2000,(33):803-809
[46]彭文生,黄华梁等.机械设计.武汉,华中理工大学出版社,1996,126-127
[47]Sedighi.M,Mohammadi.M.On The Static and Dynamic Analysis of a SmallSatellite (MESBAH).Acta Astronautica.2003,52(9):1007-1012
[48]樊振将.机械振动及其计算机辅助测试[M],北京:机械工业出版社,1996,32-37