加工误差驱动的数控插齿机设计方法研究
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摘要
齿轮加工机床是典型的复杂机械多体系统,是军事国防、航空航天、化工、冶金、采矿、风力发电的关键制造装备。齿轮加工机床精度要求高,功能、结构复杂,体积、自重大,传统的经验设计或缺少系统级优化的“现代设计”难以胜任,迫切需要先进的设计理论、方法和技术的指导与支撑。
本文在分析齿轮加工机床的系统性能和加工误差产生机理的基础上,提出了加工误差描述方法;以“性能驱动设计”为基本理念,以齿轮加工误差为驱动,以广义确定性多体系统为理论基础,研究了数控插齿机加工误差精细分析和系统集成设计方法。本文主要研究工作和成果如下:
1.系统分析了数控插齿机性能和齿轮误差,研究了插齿加工误差的产生原因和齿面几何误差的形成机理,确定了在齿轮啮合线上计算齿轮几何加工误差的一致性评价准则。
2.根据插齿机的概念运动构型和典型误差形式,将广义确定性多体系统理论和齿轮啮合理论相结合,考虑数控机床运动副的运动特性和齿轮展成加工要求,建立了描述齿轮加工机床双运动链构型的广义确定性多体系统模型。
3.通过分析插齿刀插削瞬时形成渐开螺旋面的几何特性和啮合特性,建立了刀具-工件子系统的多体系统模型;基于该模型建立了插齿加工的误差模型,将广义多体系统运动学理论和共轭曲面的离散解析原理相结合,实现了加工误差求解。
4.根据数控插齿机传动链系统特点,分析了传动链精度及其对齿轮加工误差的影响,将传动链误差的传递模型和平面齿轮啮合微分几何原理相结合,建立了反映加工误差的啮合线增量误差模型。
5.基于上述理论成果和iSIGHT软件集成平台,提出了插齿机系统设计方法及集成软件框架,并以YK51200数控插齿机产品设计为例,验证了插齿机系统设计方法和集成软件平台的有效性和实用性。
Gear machine is critical manufacturing equipment in many industries, such as national defense industry, aerospace industry, chemical industry, metallurgical industry and mining industry etc.. Having characteristics of complex function and structure, gear machine is a typical complex mechanical multi-body system. Satisfying machine is hard to be designed using design method lacking system-level design optimization and method based on traditional experiences. Therefore, it is urgent to do the work of finding advanced design theory and methods to guide and improve machine design.
Based on analyzing performance of gear machining system and mechanism of machining error, the description method of machining error was presented for gear machine. According to the performance-driven design concept and generalized multi-body certainty theory, driven by gear machining error, machining error fine model and system integrated design method of CNC gear shaper was studied.
In this dissertation, research work and results are as follows:
1. Performance of CNC gear machine and gear error was analyzed. Causes inducing gear machining error and mechanism forming tooth surface geometrical error was studied. Consistency evaluation criteria of gear geometrical machining error calculated on the gear meshing line was identified.
2. Combining the generalized certainty multi-body system theory with gear meshing theory, considering the behavior characteristics of CNC machine tools and gear-processing requirements, the multi-body system model describing double-strand configuration of gear machine was established according to concept movement configuration and typical errors of gear shaper.
3. The multi-body model based on tool-workpiece subsystem was established by analyzing the geometric characteristics and mating characteristics of involute spiral surface during slotting. Shaper processing error model was thus obtained. Combining the generalized multi-body system kinematics theory with the discrete analytic principle of conjugate surface, the solution of machining error was completed.
4. According to transmission chain characteristics of CNC machine system, the accuracy of transmission chain and its influence on gear machining error was analyzed. The meshing line incremental error model reflecting machining error was established by combining the transmission chain error model with the differential geometry principle of plane gear meshing.
5. Based on the above theoretical results and iSIGHT software integration platform, design method and system integration software framework was put forward. The product design example of YK51200 CNC gear shaper was used to illustrate the effectiveness and practicality.
本文在分析齿轮加工机床的系统性能和加工误差产生机理的基础上,提出了加工误差描述方法;以“性能驱动设计”为基本理念,以齿轮加工误差为驱动,以广义确定性多体系统为理论基础,研究了数控插齿机加工误差精细分析和系统集成设计方法。本文主要研究工作和成果如下:
1.系统分析了数控插齿机性能和齿轮误差,研究了插齿加工误差的产生原因和齿面几何误差的形成机理,确定了在齿轮啮合线上计算齿轮几何加工误差的一致性评价准则。
2.根据插齿机的概念运动构型和典型误差形式,将广义确定性多体系统理论和齿轮啮合理论相结合,考虑数控机床运动副的运动特性和齿轮展成加工要求,建立了描述齿轮加工机床双运动链构型的广义确定性多体系统模型。
3.通过分析插齿刀插削瞬时形成渐开螺旋面的几何特性和啮合特性,建立了刀具-工件子系统的多体系统模型;基于该模型建立了插齿加工的误差模型,将广义多体系统运动学理论和共轭曲面的离散解析原理相结合,实现了加工误差求解。
4.根据数控插齿机传动链系统特点,分析了传动链精度及其对齿轮加工误差的影响,将传动链误差的传递模型和平面齿轮啮合微分几何原理相结合,建立了反映加工误差的啮合线增量误差模型。
5.基于上述理论成果和iSIGHT软件集成平台,提出了插齿机系统设计方法及集成软件框架,并以YK51200数控插齿机产品设计为例,验证了插齿机系统设计方法和集成软件平台的有效性和实用性。
Gear machine is critical manufacturing equipment in many industries, such as national defense industry, aerospace industry, chemical industry, metallurgical industry and mining industry etc.. Having characteristics of complex function and structure, gear machine is a typical complex mechanical multi-body system. Satisfying machine is hard to be designed using design method lacking system-level design optimization and method based on traditional experiences. Therefore, it is urgent to do the work of finding advanced design theory and methods to guide and improve machine design.
Based on analyzing performance of gear machining system and mechanism of machining error, the description method of machining error was presented for gear machine. According to the performance-driven design concept and generalized multi-body certainty theory, driven by gear machining error, machining error fine model and system integrated design method of CNC gear shaper was studied.
In this dissertation, research work and results are as follows:
1. Performance of CNC gear machine and gear error was analyzed. Causes inducing gear machining error and mechanism forming tooth surface geometrical error was studied. Consistency evaluation criteria of gear geometrical machining error calculated on the gear meshing line was identified.
2. Combining the generalized certainty multi-body system theory with gear meshing theory, considering the behavior characteristics of CNC machine tools and gear-processing requirements, the multi-body system model describing double-strand configuration of gear machine was established according to concept movement configuration and typical errors of gear shaper.
3. The multi-body model based on tool-workpiece subsystem was established by analyzing the geometric characteristics and mating characteristics of involute spiral surface during slotting. Shaper processing error model was thus obtained. Combining the generalized multi-body system kinematics theory with the discrete analytic principle of conjugate surface, the solution of machining error was completed.
4. According to transmission chain characteristics of CNC machine system, the accuracy of transmission chain and its influence on gear machining error was analyzed. The meshing line incremental error model reflecting machining error was established by combining the transmission chain error model with the differential geometry principle of plane gear meshing.
5. Based on the above theoretical results and iSIGHT software integration platform, design method and system integration software framework was put forward. The product design example of YK51200 CNC gear shaper was used to illustrate the effectiveness and practicality.
引文
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