滚齿误差及补偿技术研究
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摘要
齿轮是机械行业量大面广的基础件,在生产和制造领域占有极其重要的地位。滚齿加工是齿轮加工的重要手段。随着滚齿技术的发展,人们对滚齿机床及工艺系统的刚度和精度要求更高。提高机床的精度,减小机床的误差有着十分重要的意义。本文对YKX3132G型六轴滚齿机床的误差、误差模型及造成误差的热致变形、力致变形等进行详细的理论分析,设计并建立起完整的实验系统,进行了一系列的试验,建立起滚齿加工热误差模型。
文中对滚齿加工中机床刀具与工件间的各种位置变化对齿轮加工精度的影响,对滚齿加工过程中刀具相对工件偏差的变化速度对加工精度的影响进行了全面的分析。利用坐标变换的方法,建立起六轴滚齿机的误差数学模型。
针对滚齿加工自身特点、滚齿切削力的变化规律,对滚齿加工中力致误差和YKX3132G型数控六轴滚齿机加工工艺系统刚度进行了详细的分析和研究,并导出系统刚度理论计算公式。
系统地对滚齿机床因热致误差造成的刀具、工件偏差及其补偿技术进行了研究。研究包括机床误差的理论分析、试验安排、试验研究、数据处理方法、热变形系统的辨识和误差的补偿方法等。
针对滚齿机床的结构特点,分析了滚齿机床热源及减小热误差变形的方法,导出这种型式机床热变形造成的刀具与工件间线性误差和角度误差的数学模型。对滚齿加工中的数据处理方法进行了分析研究,特别是对数据的筛选方法进行了重点的分析和研究。对神经网络、回归分析等方法用于齿轮加工进行了研究,用逐步回归与径向基神经网络结合对YKX3132G型滚齿机床热致变形进行系统辨识,并成功地建立滚齿机床热致误差模型,结果表明,效果良好。
对滚齿加工工艺系统的误差补偿方法进行了分析和研究。讨论了滚齿误差的补偿方法的特点,针对滚齿加工中几何误差、力致变形误差和热致变形误差各自的特点,提出了相应的补偿方法。
Gear is a widely used element in manufacturing industry and plays a very important role in manufacturing. Hobbing is an important means for gear manufacturing. With the development of hobbing technology, high rigidity and precision is needed for hobbing machine and its process system, and therefore it makes sense to increase precision and diminish error of the machine. The errors of YKX3132G six axes hobbing machine are studied in the dissertation. An error model is proposed and errors caused by thermal- and force-induced deformation etc. are analyzed theoretically in detail. A complete experimental system is developed and a thermal error model for hobbing is built based on a series of tests.The factors effecting hobbing precision are analyzed systematically, including relative position and velocity variation between cutter and workpiece. A mathematical model of errors for six axes hobbing machine is built by coordinates transformation.Force-induced deformation and process system rigidity of YKX3132G six axes hobbing machine are studied in detail according to the characteristic and variation rule of cutting force in hobbing, and a theoretical formula for system rigidity is proposed.The error of cutter and workpiece caused by thermal-induced deformation and its compensating technique is studied systematically, including theoretical analyses for machine error, experiment setup, experimental study, data processing, system identification of thermal-induced deformation, and error compensation etc.Heat source of hobbing and method for thermal-induced deformation decrease are analyzed according to structural characteristic of hobbing machine, and its mathematical model for position and angle error between cutter and workpiece caused by thermal-induced deformation. Practical data processing is studied and data screening is focused. The use of neural network (NN), regression analyses etc. in gear manufacturing is explored. The system of the
thermal-induced deformation of the hobbing machine is identified by combining stepwise regression and radial base neural network. It is applied successfully to error modeling for thermal-induced deformation and results in a good performance.Error compensating technique for the process system of hobbing is studied. Characteristic of hobbing error compensation is discussed. Error compensating techniques for geometric error and errors caused by thermal- and force-induced deformation are proposed according to their characteristic.
文中对滚齿加工中机床刀具与工件间的各种位置变化对齿轮加工精度的影响,对滚齿加工过程中刀具相对工件偏差的变化速度对加工精度的影响进行了全面的分析。利用坐标变换的方法,建立起六轴滚齿机的误差数学模型。
针对滚齿加工自身特点、滚齿切削力的变化规律,对滚齿加工中力致误差和YKX3132G型数控六轴滚齿机加工工艺系统刚度进行了详细的分析和研究,并导出系统刚度理论计算公式。
系统地对滚齿机床因热致误差造成的刀具、工件偏差及其补偿技术进行了研究。研究包括机床误差的理论分析、试验安排、试验研究、数据处理方法、热变形系统的辨识和误差的补偿方法等。
针对滚齿机床的结构特点,分析了滚齿机床热源及减小热误差变形的方法,导出这种型式机床热变形造成的刀具与工件间线性误差和角度误差的数学模型。对滚齿加工中的数据处理方法进行了分析研究,特别是对数据的筛选方法进行了重点的分析和研究。对神经网络、回归分析等方法用于齿轮加工进行了研究,用逐步回归与径向基神经网络结合对YKX3132G型滚齿机床热致变形进行系统辨识,并成功地建立滚齿机床热致误差模型,结果表明,效果良好。
对滚齿加工工艺系统的误差补偿方法进行了分析和研究。讨论了滚齿误差的补偿方法的特点,针对滚齿加工中几何误差、力致变形误差和热致变形误差各自的特点,提出了相应的补偿方法。
Gear is a widely used element in manufacturing industry and plays a very important role in manufacturing. Hobbing is an important means for gear manufacturing. With the development of hobbing technology, high rigidity and precision is needed for hobbing machine and its process system, and therefore it makes sense to increase precision and diminish error of the machine. The errors of YKX3132G six axes hobbing machine are studied in the dissertation. An error model is proposed and errors caused by thermal- and force-induced deformation etc. are analyzed theoretically in detail. A complete experimental system is developed and a thermal error model for hobbing is built based on a series of tests.The factors effecting hobbing precision are analyzed systematically, including relative position and velocity variation between cutter and workpiece. A mathematical model of errors for six axes hobbing machine is built by coordinates transformation.Force-induced deformation and process system rigidity of YKX3132G six axes hobbing machine are studied in detail according to the characteristic and variation rule of cutting force in hobbing, and a theoretical formula for system rigidity is proposed.The error of cutter and workpiece caused by thermal-induced deformation and its compensating technique is studied systematically, including theoretical analyses for machine error, experiment setup, experimental study, data processing, system identification of thermal-induced deformation, and error compensation etc.Heat source of hobbing and method for thermal-induced deformation decrease are analyzed according to structural characteristic of hobbing machine, and its mathematical model for position and angle error between cutter and workpiece caused by thermal-induced deformation. Practical data processing is studied and data screening is focused. The use of neural network (NN), regression analyses etc. in gear manufacturing is explored. The system of the
thermal-induced deformation of the hobbing machine is identified by combining stepwise regression and radial base neural network. It is applied successfully to error modeling for thermal-induced deformation and results in a good performance.Error compensating technique for the process system of hobbing is studied. Characteristic of hobbing error compensation is discussed. Error compensating techniques for geometric error and errors caused by thermal- and force-induced deformation are proposed according to their characteristic.
引文
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