刚度时变系统非线性动力学研究及稳定性预测
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摘要
高速铣削加工技术是先进制造技术中最重要的基础技术之一,已成为21世纪先进制造技术的重要组成部分,被广泛应用于航空航天、汽车、模具、能源、轨道交通等众多领域。铣削过程中的颤振是高速铣削实现高速、高效和高精度加工的关键限制因素之一,因此大型整体薄壁件高速铣削下的稳定性预测问题成为航空工业制造技术中迫切需要解决的技术难题。以大型整体薄壁件为研究对象,以提高切削效率、保障切削稳定性为主要研究目标,围绕高速铣削过程中随工件材料快速去除工件质量和刚度时变的特点,借助理论分析和试验研究等手段,对整个铣削过程的稳定性进行系统深入的研究。
整个大型整体薄壁件高速铣削加工过程划分了刚性工件、柔性工件刚度时不变和柔性工件刚度时变三个加工阶段,分别建立时不变和时变系统的动力学模型;从工程应用角度出发,确定了工件临界刚度对应下的工件临界质量作为是否考虑工件柔性的临界判据,并确定了工件临界质量值;分析高速铣削过程中,动态铣削力和工件刚度随材料切除在不同剩余壁厚和刀具作用位置时系统动态特性(模态参数、频响函数)及其变化规律。
基于所建立的大型整体薄壁件刚性工件、柔性工件刚度时不变和柔性工件刚度时变阶段动力学模型来进行稳定性预测分析,针对柔性工件刚度时变阶段的质量、刚度等参数时变的特性,利用灵敏度法分析了工件质量和刚度变化对高速铣削系统模态特性的贡献灵敏度,依据动态响应输出信号(output only)法确定质量、刚度等多参数时变系统的频响函数,利用matlab仿真技术绘制了整个铣削过程不同阶段的稳定性lobe图(SLD)。
研究夹具数量、夹具装夹位置和工件剩余壁厚等因素对大型整体薄壁件高速铣削系统稳定性的影响规律,分别绘制了薄壁件铣削系统的稳定性极限图。分析装夹方案对稳定性的影响,所得结果表明夹具对称且均匀分布可增强系统稳定性。提出并建立了基于铣削稳定性的装夹方案流程图。
高速铣削系统动态试验研究,设计并实施了钛合金整体薄壁件的模态试验、空转试验和铣削试验。为刚度时变系统的结构动力学特性分析,铣削稳定性分析提供试验数据验证。
High speed milling(HSM),which is one of the advanced manufacturing technologies,has been become the important part of modern manufacture technology in 21st century and used in many different field,e.g.aeronautics,automobile,die and mould,energy,and rail transit.While the material removal rate(MRR),reflecting the machining efficiency,is often limited by the occurrence of an instability phenomenon called chatter in HSM processes.Practices and studies have been proven that chatter plays an important role in high speed milling.So the vibration of the thin wall integral structure is an urgent problem in the aviation machining industry.In this paper,the time-varying quality and stiffness of the thin wall integral structure is studied,the stability is obtained by theoretical analysis and experimental validation.
The dynamics model of high-speed milling system with time-varying parameters is established.For the characteristics of time-varying quality and stiffness with the change of the remaining wall thickness,the multi-degree freedom model of the tool and the time-varying nonlinear dynamics model of the flexible workpiece are built;Based on the dynamic response of the output signal(output only),it is determined that the quality, stiffness and other parameters of time-varying system frequency response function. From the view of engineering application,the critical stiffness of workpiece corresponding to the critical mass is identified as the critical criterion.The critical mass is obtained according to the different structures of machine tools,tools and workpiece;
Stability forecast analysis is carried out based on the dynamic model which is built in the rigid,the no time varying stiffness of the flexible and time varying stiffness of the flexible.For the time-varying properties of the quality and stiffness in time varying stiffness of the flexible,modal sensitivity analysis is used to analyze the sensitivity which is made by the quality and stiffness of workpiece.FRF is defmited based on dynamic response output signal(output only) with the parameters of quality and stiffness.The stability lobe diagram(SLD) of the whole milling process is drawn with the matlab simulation;
Studying the influential discipline of stability from the influential elements such as clamping number,clamping position and the remaining wall thickness,and then the stability lobe of the thin walled workpiece is separately drawn.Analysing the stability influence from clamping number.clamping position and the remaining wall thickness can strengthen the system stability.The flow chart of clamping based on stability is raised and built;
Experimentations of modal analysis,idling of spindle and high-speed milling are designed and carried out to investigate and validate the dynamics models,theory and method proposed and the dynamic characteristics.The experimental methods suitable for performance examination and evaluation of HSM system with respect to stability are researched and established.
整个大型整体薄壁件高速铣削加工过程划分了刚性工件、柔性工件刚度时不变和柔性工件刚度时变三个加工阶段,分别建立时不变和时变系统的动力学模型;从工程应用角度出发,确定了工件临界刚度对应下的工件临界质量作为是否考虑工件柔性的临界判据,并确定了工件临界质量值;分析高速铣削过程中,动态铣削力和工件刚度随材料切除在不同剩余壁厚和刀具作用位置时系统动态特性(模态参数、频响函数)及其变化规律。
基于所建立的大型整体薄壁件刚性工件、柔性工件刚度时不变和柔性工件刚度时变阶段动力学模型来进行稳定性预测分析,针对柔性工件刚度时变阶段的质量、刚度等参数时变的特性,利用灵敏度法分析了工件质量和刚度变化对高速铣削系统模态特性的贡献灵敏度,依据动态响应输出信号(output only)法确定质量、刚度等多参数时变系统的频响函数,利用matlab仿真技术绘制了整个铣削过程不同阶段的稳定性lobe图(SLD)。
研究夹具数量、夹具装夹位置和工件剩余壁厚等因素对大型整体薄壁件高速铣削系统稳定性的影响规律,分别绘制了薄壁件铣削系统的稳定性极限图。分析装夹方案对稳定性的影响,所得结果表明夹具对称且均匀分布可增强系统稳定性。提出并建立了基于铣削稳定性的装夹方案流程图。
高速铣削系统动态试验研究,设计并实施了钛合金整体薄壁件的模态试验、空转试验和铣削试验。为刚度时变系统的结构动力学特性分析,铣削稳定性分析提供试验数据验证。
High speed milling(HSM),which is one of the advanced manufacturing technologies,has been become the important part of modern manufacture technology in 21st century and used in many different field,e.g.aeronautics,automobile,die and mould,energy,and rail transit.While the material removal rate(MRR),reflecting the machining efficiency,is often limited by the occurrence of an instability phenomenon called chatter in HSM processes.Practices and studies have been proven that chatter plays an important role in high speed milling.So the vibration of the thin wall integral structure is an urgent problem in the aviation machining industry.In this paper,the time-varying quality and stiffness of the thin wall integral structure is studied,the stability is obtained by theoretical analysis and experimental validation.
The dynamics model of high-speed milling system with time-varying parameters is established.For the characteristics of time-varying quality and stiffness with the change of the remaining wall thickness,the multi-degree freedom model of the tool and the time-varying nonlinear dynamics model of the flexible workpiece are built;Based on the dynamic response of the output signal(output only),it is determined that the quality, stiffness and other parameters of time-varying system frequency response function. From the view of engineering application,the critical stiffness of workpiece corresponding to the critical mass is identified as the critical criterion.The critical mass is obtained according to the different structures of machine tools,tools and workpiece;
Stability forecast analysis is carried out based on the dynamic model which is built in the rigid,the no time varying stiffness of the flexible and time varying stiffness of the flexible.For the time-varying properties of the quality and stiffness in time varying stiffness of the flexible,modal sensitivity analysis is used to analyze the sensitivity which is made by the quality and stiffness of workpiece.FRF is defmited based on dynamic response output signal(output only) with the parameters of quality and stiffness.The stability lobe diagram(SLD) of the whole milling process is drawn with the matlab simulation;
Studying the influential discipline of stability from the influential elements such as clamping number,clamping position and the remaining wall thickness,and then the stability lobe of the thin walled workpiece is separately drawn.Analysing the stability influence from clamping number.clamping position and the remaining wall thickness can strengthen the system stability.The flow chart of clamping based on stability is raised and built;
Experimentations of modal analysis,idling of spindle and high-speed milling are designed and carried out to investigate and validate the dynamics models,theory and method proposed and the dynamic characteristics.The experimental methods suitable for performance examination and evaluation of HSM system with respect to stability are researched and established.
引文
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