异型轧辊数控加工机床模拟设计及运动仿真研究
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摘要
在当今的工程领域中,非圆截面零件以其独特的优越性,在生产中所占的比例日益增加,为了达到性能要求,其加工精度要求也随之提高。轧辊是轧机的重要部件之一,它是轧机的主要变形工具,直接决定着生产工艺的合理性和产品的经济性,因此加工出满足轧制需要的轧辊是轧钢技术的关键。异型轧辊属于非圆截面零件,能够产生特殊的运动规律,但其孔型形状独特,设计和加工相对困难,成为轧辊研究领域的一个重要课题。
本课题主要针对异型轧辊复杂孔型曲面的加工问题,深入研究轧辊孔型曲面的拟合方法和数控机床的传动系统,并对加工工艺进行了分析。本文分析了异型轧辊孔型曲面的特点,根据已知离散点,应用以阿基米德螺旋线方程作基函数的最小二乘法和三次样条拟合方法对轧辊横截面外廓曲线进行拟合;采用数控车削加工方案,分析了数控车床刀具径向进给的运动特性,为制定轧辊零件车削加工工艺提供技术依据;研究非圆截面零件车削进给系统的层次模型,完成了异型轧辊数控加工车床进给系统的结构设计;对机床的进给系统进行运动学仿真,分析位移、速度和加速度曲线的特点和变化情况,并证明曲线拟合方法的可行性;通过研究刀尖的半径补偿方法和异型轧辊数控加工程序编制方法,提出提高机床加工精度的主要措施。
以上研究结论不只是针对异型轧辊的加工而提出的,对于其它非圆截面零件的加工同样具有参考意义,为进一步研究非圆截面零件的车削加工提供了良好的理论基础。
In the contemporary engineering domain, the application of the noncircular cross section work in the production proportion increases increasingly because of its unique superiority, and its precision also improves to achieve the performance need. Roller is one of the important parts and main distortion tool of rolling mill. It determines the technics rationality and product economy directly. Therefore, it is the essential technology of steel rolling technology to processes satisfied roller. Noncircular cross section roller can bring special motion, but it is difficult to design and machining owing to its unique processing’s surface outline. This becomes an important problem in the researching domain of the roller.
The processing of the complicated groove surface of noncircular cross section roller is researched, the method of curve fit of roll’s groove and the transmission system of numerically controlled machine tool is deeply studied, and the processing technology is analyzed in this paper. The processing’s surface outline of the roll based on analyzing surface specialties of noncircular cross section roller is designed, using the least-squares method based on Archimedes Spiral and the cubic spline method of curve fit. Turning and motion properties of feeding system of the NC lathe, which provide technology support for the processing technology are designed and analyzed. The layered structure of feeding system of the noncircular cross section work and the structure design of feeding system of the NC lathe for making noncircular cross section roller are analyzed. Kinematics analysis of feeding system is made, the variational rule and the trait of the displacement are got, velocity and acceleration in the machining process with analyzing three curve diagrams are analyzed, and the feasibility of the curve fit method is proved. The main method of enhancing the processing precision based on studying the means of radius lathe and processing programming of NC lathe for noncircular cross section roller are introduced.
The conclusions studied above is not presented for noncircular cross section roller machining, but referenced for other noncircular cross section works. It provides favorable theory for more research of the noncircular cross section turning.
本课题主要针对异型轧辊复杂孔型曲面的加工问题,深入研究轧辊孔型曲面的拟合方法和数控机床的传动系统,并对加工工艺进行了分析。本文分析了异型轧辊孔型曲面的特点,根据已知离散点,应用以阿基米德螺旋线方程作基函数的最小二乘法和三次样条拟合方法对轧辊横截面外廓曲线进行拟合;采用数控车削加工方案,分析了数控车床刀具径向进给的运动特性,为制定轧辊零件车削加工工艺提供技术依据;研究非圆截面零件车削进给系统的层次模型,完成了异型轧辊数控加工车床进给系统的结构设计;对机床的进给系统进行运动学仿真,分析位移、速度和加速度曲线的特点和变化情况,并证明曲线拟合方法的可行性;通过研究刀尖的半径补偿方法和异型轧辊数控加工程序编制方法,提出提高机床加工精度的主要措施。
以上研究结论不只是针对异型轧辊的加工而提出的,对于其它非圆截面零件的加工同样具有参考意义,为进一步研究非圆截面零件的车削加工提供了良好的理论基础。
In the contemporary engineering domain, the application of the noncircular cross section work in the production proportion increases increasingly because of its unique superiority, and its precision also improves to achieve the performance need. Roller is one of the important parts and main distortion tool of rolling mill. It determines the technics rationality and product economy directly. Therefore, it is the essential technology of steel rolling technology to processes satisfied roller. Noncircular cross section roller can bring special motion, but it is difficult to design and machining owing to its unique processing’s surface outline. This becomes an important problem in the researching domain of the roller.
The processing of the complicated groove surface of noncircular cross section roller is researched, the method of curve fit of roll’s groove and the transmission system of numerically controlled machine tool is deeply studied, and the processing technology is analyzed in this paper. The processing’s surface outline of the roll based on analyzing surface specialties of noncircular cross section roller is designed, using the least-squares method based on Archimedes Spiral and the cubic spline method of curve fit. Turning and motion properties of feeding system of the NC lathe, which provide technology support for the processing technology are designed and analyzed. The layered structure of feeding system of the noncircular cross section work and the structure design of feeding system of the NC lathe for making noncircular cross section roller are analyzed. Kinematics analysis of feeding system is made, the variational rule and the trait of the displacement are got, velocity and acceleration in the machining process with analyzing three curve diagrams are analyzed, and the feasibility of the curve fit method is proved. The main method of enhancing the processing precision based on studying the means of radius lathe and processing programming of NC lathe for noncircular cross section roller are introduced.
The conclusions studied above is not presented for noncircular cross section roller machining, but referenced for other noncircular cross section works. It provides favorable theory for more research of the noncircular cross section turning.
引文
[1] 石岩. 数控技术的发展趋势和思考. 理论研究,2007:50.
[2] Kakino Y.,Ihara Y.,Nakatsu Y.,A study on the motion accuracy of NC machine tools,Precision Eng. 1986,52(10):1739-1745.
[3] H.D. Kwon,M. Burdekin,Adjustment of CNC machine tool controller setting various by an experimental method,Int. J. Mach. Tools Manufact. 1998,38(9):1045-1065.
[4] Katz R, Min B-K, Pasek Z. Open Architecture Control Technology Trends. ERC/RMS Report 35 (The University of Michigan). 2000-9-10.
[5] 张承瑞. 数控技术发展趋势. 现代制造技术与装备,2007,(2):3-6.
[6] OSACA(Open SystemArchitecture for Controls within AutomationSystems,ESPRIT III project) Final Report,February 21,1996.
[7] Qin H.,Ohoka M.,Yamamoto J. Manufacturing accuracy of contours with a machining center, 1994(31):27-34.
[8] Kwon H.D.,Burdekin M. Development and application of a system for evaluating the free-drive errors on computer numerically controlled machine tools,Precision Eng. 1996,19(2/3):133-140.
[9] Kynast R. Digital Drive Interface. SERCOS Interface, pp.10- 13 Vogel Verlag,Berlin. 2004
[10] Lutz P. Sercon 816- Controller for Sercon Interface. SERCOSInterface,pp. 10- 13 Vogel Verlag, Berlin. 2004
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[19] 卜基桥. 新型并联加工机床. 现代金属加工,2007,6:12-13.
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[21] 吴迪. 微型计算机辅助孔型设计. 沈阳: 东北大学出版社, 1993.
[22] Kouono H. CAD/ CAM system for roll pass design. 19. Int Machine Tool Design, a. Res conference Manchester, 1978: 23-27.
[23] Nillson R. Computerized roll pass design of steel angle Arch. Eisenhiittenwesen, 1981 : 16-18.
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[31] Kim S H. A knowledge-based expert system for roll pass and profile design for shape rolling of round and square bars [J]. Journal of Materials Processing Technology, 1999 , 189(90) : 145-151.
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[40] Rakowski, Leo R. New piston line knocks Chrysler's-block off. Machine and Tool Blue Book. 1988,7 v83 n7 p34-36.
[41] 马骋,冯之敬,赵广木等.活塞立体靠模的数控车削.清华大学学报,1999,39(4):28-31.
[42] Astrop Arthur. NEW LATHE OFFERS‘INSTANT’ RELIEF. Machinery and Production Engineering. 1984,3 042 n3644 p42-44.
[43] Wang Yuan-Chuan, Lee An-Chen, Lin Long-Chin. Complex piston contour machining using a Digital Cam system. journal of the Chinese Society of Mechanical Engineers. 1988,10 v9 n5 p 361-370.
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[45] 贾晨辉,张浩,陆剑峰. 虚拟生产系统规划与仿真. 组合机床与自动化加工技术,2006,(8):94.
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[2] Kakino Y.,Ihara Y.,Nakatsu Y.,A study on the motion accuracy of NC machine tools,Precision Eng. 1986,52(10):1739-1745.
[3] H.D. Kwon,M. Burdekin,Adjustment of CNC machine tool controller setting various by an experimental method,Int. J. Mach. Tools Manufact. 1998,38(9):1045-1065.
[4] Katz R, Min B-K, Pasek Z. Open Architecture Control Technology Trends. ERC/RMS Report 35 (The University of Michigan). 2000-9-10.
[5] 张承瑞. 数控技术发展趋势. 现代制造技术与装备,2007,(2):3-6.
[6] OSACA(Open SystemArchitecture for Controls within AutomationSystems,ESPRIT III project) Final Report,February 21,1996.
[7] Qin H.,Ohoka M.,Yamamoto J. Manufacturing accuracy of contours with a machining center, 1994(31):27-34.
[8] Kwon H.D.,Burdekin M. Development and application of a system for evaluating the free-drive errors on computer numerically controlled machine tools,Precision Eng. 1996,19(2/3):133-140.
[9] Kynast R. Digital Drive Interface. SERCOS Interface, pp.10- 13 Vogel Verlag,Berlin. 2004
[10] Lutz P. Sercon 816- Controller for Sercon Interface. SERCOSInterface,pp. 10- 13 Vogel Verlag, Berlin. 2004
[11] 张曙. 开放式数控系统的现状和趋势. 数控与软件,2007,2(1):84-87.
[12] 刘飞,曹华军, 张华等. 绿色制造的理论与技术. 北京: 科学出版社, 2005.
[13] 刘光复,刘志峰,李钢等. 绿色设计与绿色制造. 北京: 机械工业出版社, 1999.
[14] 高建刚, 武英, 向东等. 机电产品拆卸研究综述. 机械工程学报,2004,40(7): 129.
[15] 汪劲松,朱煜,张华等. 并联机床虚拟产品设计系统及基本框架研究. 计算机集成制造系统-CIMS,2001,7 (5):57-62.
[16] 汪劲松,黄田. 并联机床——机床行业面临的机遇与挑战. 中国机械工程,1999,10 (10):1103-1107.
[17] 范晋伟,关佳亮,王彤波等. 并联机床虚拟设计的理论方法. 北京工业大学学报,2001, 27(4):441-446.
[18] 黄真. 并联机器人机构学基础理论的研究. 机器人技术与应用,2001(6):11～14.
[19] 卜基桥. 新型并联加工机床. 现代金属加工,2007,6:12-13.
[20] Berkovskii V S. Computer-aided roll pass design. Steel in translation, 2000,(2): 32-35.
[21] 吴迪. 微型计算机辅助孔型设计. 沈阳: 东北大学出版社, 1993.
[22] Kouono H. CAD/ CAM system for roll pass design. 19. Int Machine Tool Design, a. Res conference Manchester, 1978: 23-27.
[23] Nillson R. Computerized roll pass design of steel angle Arch. Eisenhiittenwesen, 1981 : 16-18.
[24] Kenndy K F , Altan T. Computer-aided analysis is of metal flow stress and roll pass design in rod rolling. Iron and Steel Engineer, 1993 , (6): 31-33.
[25] (苏)斯米尔诺夫. 轧辊孔型设计. 北京: 冶金工业出版社, 1991.
[26] 唐文林. 简单断面型钢计算机辅助优化孔型设计的研究. 西安建筑科技大学学报, 2000 , (6):27-29.
[27] 赵松筠. 复二重式线材轧机计算机优化孔型设计实践. 轧钢,1993, (2): 17-20.
[28] Hartley P , Pillinger I. Developments in computational modeling techniques for industrial metal forming process[J]. Proceedings of the Institution of Mechanical Engineers, PartB: Journal of Engineering Manufacture , 2001 , 215 (B7): 903-914.
[29] Jung J Y. Fuzzy algorithm for calculating roll speed variation based on roll separating force in hot rolling[J]. International Journal of Mechanical Sciences, 2000 , 42 (2) : 249-272.
[30] Pichler R , Pfaffermayr M. Neural networks for on-line optimization of the rolling process [J] . Iron and Steel Review , 2000 , 40 (3) : 46-56.
[31] Kim S H. A knowledge-based expert system for roll pass and profile design for shape rolling of round and square bars [J]. Journal of Materials Processing Technology, 1999 , 189(90) : 145-151.
[32] 邓中亮. 非圆截面工件加工法的发展[J]. 制造技术与机床,1996,9:48-51.
[33] 邓中亮. 异型零件的几种车削加工方法[J]. 机械制造,1994,1:6-9.
[34] 孙永强. 冯之敬等.国内活塞异形外圆车削加工技术的现状[J].机械工程师,2002,3:7-9.
[35] 刘山,葛思华,丁崇生. 用于异圆加工的动铁式直线电机. 微特电机,1999,2:26.
[36] 刘金凌等. 中突变椭圆活塞数控车削技术[J].组合机床与加工自动化,1994,4:16-18.
[37] 廖德岗. 异形柱面数控车铣组合加工成形机理研究[J]. 机械工程师,2005,6:45-47.
[38] 易红. 数控技术. 机械工业出版社,2005,8.
[39] Freeman. Nancy Brooke TURNING OUT PISTON ASSEMBLIES. American Machinist. 1982,2v126 n2 p118-119.
[40] Rakowski, Leo R. New piston line knocks Chrysler's-block off. Machine and Tool Blue Book. 1988,7 v83 n7 p34-36.
[41] 马骋,冯之敬,赵广木等.活塞立体靠模的数控车削.清华大学学报,1999,39(4):28-31.
[42] Astrop Arthur. NEW LATHE OFFERS‘INSTANT’ RELIEF. Machinery and Production Engineering. 1984,3 042 n3644 p42-44.
[43] Wang Yuan-Chuan, Lee An-Chen, Lin Long-Chin. Complex piston contour machining using a Digital Cam system. journal of the Chinese Society of Mechanical Engineers. 1988,10 v9 n5 p 361-370.
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