基于磁流变力矩伺服的非球面气囊抛光技术研究
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摘要
近年来，随着人们对智能材料——磁流变液认识水平的不断提高，以及精密加工和制造技术的快速发展，使得磁流变液在精密加工领域的应用越来越受到国内外专家和学者的关注。在相关领域的诸多研究成果中，关于磁流变液器件以及应用方面阐述较多。不少学者将磁流变液直接作为工作介质用于抛光加工，但将其应用到力矩伺服装置用于气囊抛光加工的却鲜有报道。
本文结合国家自然科学基金项目“模具曲面数控研抛的柔顺控制研究(50705044)”，在课题组成员前期工作的基础上，针对目前国内外关于非球面工件研抛加工中普遍存在的力/位耦合不易控制，以及采用机器人辅助气囊加工刚度差等难点问题，提出了一种基于磁流变力矩伺服（MRT）的新型气囊抛光方法，改变了以往通过调整气囊内部压力的加载方式，用MRT为气囊抛光系统提供合适的抛光力，控制方法简单。在自行研制的气囊抛光实验样机上进行了工艺实验研究，通过对非球面工件抛光加工实验，取得了较理想的效果。论文主要研究内容、技术方法及结论如下：
1.在对课题相关内容进行大量调研的前提下，总结了目前国内外磁流变液以及器件应用和开发的现状，以及气囊抛光技术的发展现状。综合分析磁流变效应的特点以及气囊抛光方法在非球面加工领域的优越性，提出了本文的研究内容。
2.运用传统抛光理解和接触力学相关知识，分析了抛光加工过程中抛光力与气囊工具位姿之间的耦合关系；研究了抛光膜、工件及磨粒之间的接触变形关系。研究表明，抛光过程中气囊工具的位姿受接触区法向位移变形的影响。为了保证法向位移量对气囊抛光加工表面质量不产生影响，必须在刀具进给程序中考虑法向位移的影响，并需要不断补偿。同时总结得出接触区抛光速度、抛光压力的分布规律，以Preston方程为依据，建立了材料去除模型。
3.基于MRT力矩伺服的气囊抛光实验样机的研制。进行了MRT结构设计及力矩测试实验，研制了气囊抛光工具系统，实现了气囊抛光过程中力/位分离同步控制。推导了位置空间内机床坐标、刀具坐标之间的关系。
4.为了进一步开展气囊抛光实验，搭建了气囊抛光系统硬件平台，建立了抛光力控制模型，设计了电流源、抛光力相关控制软件，并介绍了非球面工件基于MasterCAM软件生成数控代码的过程。
5.气囊抛光工艺实验及非球面工件气囊抛光实验。分析气囊压缩量、励磁电流、姿态角以及气囊转速等工艺参数对接触区特性影响规律。应用此种新型气囊抛光方法对实际抛物面工件进行气囊抛光，获得表面粗糙度Ra=29nm的光滑表面。
本文将磁流变液应用于力矩伺服装置，将其作为一种加载机构成功应用于非球面气囊抛光加工中，提出了一种基于MRT的新型气囊抛光方法，在国内外关于气囊抛光的研究中尚未见正式报道。实际应用表明，将MRT技术与气囊抛光技术融合，从根本上解决抛光过程中力/位耦合问题，显著提高了非球面工件加工的效率和精度，开辟了磁流变液（MRF）在超精密加工领域的新途径，拓宽了MRF这种智能材料的应用范围。
In recent years, with constantly understanding of Magnetorhelogical fluid (MRF)as wellasthe rapidly development in precision machining and manufacturing technology, as a newtype of smart material, MRF has attracted the interest of a large number of experts andscholars at home and abroad. Research on MRF devices and applications has a largeproportion in many related fields.Many scholars had used MRF as a working medium forpolishing, but its application to torque servo device used for bonnet polishing is seldomreported.
The study has been supported by the National Natural Science Foundation of Chinaunder grant No.50705044. Aspheric surface polishing is not easy to control as force andposition coupling and robot auxiliary bonnet polishing has poor rigidity. Anovelmethod ofbonnet polishing based on magnetorheological torque servo has been proposed on the basis ofthe previous work of members.It changes the loading mode while by adjusting the gasbaginternal pressure in the past. It provides proper polishing force for bonnet polishing systemusing MRT. It is easy to control. The process experimental study has been preceded in theself-developed bonnet polishing prototype and the results are better.
The main research contents, technical methods and conclusions are as follows:
1. Summarized the status and development of MRT devices and applications as well asbonnet polishing technique at home and abroad on the basis of investigation on relatedcontent. It presents the research contents of this paper through comprehensive analysis of thecharacteristics of magnetorheological effect and bonnet polishing method in the field ofpolishing aspheric surface.
2. The mechanism of polishing force and position coupling and the interactiondeformation among polishing film、abrasive and the part are analyzed on the basis of studying the traditional polishing theories and contact mechanics. The research results show that theposition of polishing tool is affected by the normal displacement between the bonnetpolishing tool and aspheric part. In order to guarantee the normal displacement has no effecton processing surface quality, it must be considered the influence of the displacement in thetool feed program and needs to keep compensation. The polishing speed and polishingpressure distribution in the contact area are deduced. According to Preston’s law, the materialremoval model has been established.
3. Development of the bonnet tool polishing experiment prototype based on MRT. Thestructure design of MRT and torque test has been launched. And the bonnet tool polishingsystem is developed. The problem of force-position coupling can be resolved. The relationbetween machine coordinate and tool coordinate in position space is deduced.
4. The bonnet polishing system hardware is built in order to further develop thepolishing experiment. The control model of the polishing force based on MRT is establishedwith the target of achieving the constant material removal rates. The related software of thecurrent source and polishing force is designed. The generation of CNC code of aspheric partis introduced based on MasterCAM.
5. Bonnet polishing process experiment and bonnet polishing of aspheric. The influencelaw on the process parameters as air compression, excitation current, attitude angle and airbagspeed in contact area characteristics is analyzed. Application of this novel polishing methodon polishing actual parabolicpart can get the smooth surface of Ra=29nm.
In short, MRF is used for torque servo system and successfully applied to bonnet toolpolishing of aspheric surface as loading mechanism. A novel method of bonnet polishing isproposed. Research about this kind of bonnet polishing method based on MRT has not beenformally reported.
Practice has proved that the fusion of the MRT technology and bonnet polishingtechnology can solute the polishing force-position coupling problem. It can significantlyimprove the efficiency and accuracy of the part. The original application of MRF in bonnetpolishing will further broaden the application field of this smart material.
本文结合国家自然科学基金项目“模具曲面数控研抛的柔顺控制研究(50705044)”，在课题组成员前期工作的基础上，针对目前国内外关于非球面工件研抛加工中普遍存在的力/位耦合不易控制，以及采用机器人辅助气囊加工刚度差等难点问题，提出了一种基于磁流变力矩伺服（MRT）的新型气囊抛光方法，改变了以往通过调整气囊内部压力的加载方式，用MRT为气囊抛光系统提供合适的抛光力，控制方法简单。在自行研制的气囊抛光实验样机上进行了工艺实验研究，通过对非球面工件抛光加工实验，取得了较理想的效果。论文主要研究内容、技术方法及结论如下：
1.在对课题相关内容进行大量调研的前提下，总结了目前国内外磁流变液以及器件应用和开发的现状，以及气囊抛光技术的发展现状。综合分析磁流变效应的特点以及气囊抛光方法在非球面加工领域的优越性，提出了本文的研究内容。
2.运用传统抛光理解和接触力学相关知识，分析了抛光加工过程中抛光力与气囊工具位姿之间的耦合关系；研究了抛光膜、工件及磨粒之间的接触变形关系。研究表明，抛光过程中气囊工具的位姿受接触区法向位移变形的影响。为了保证法向位移量对气囊抛光加工表面质量不产生影响，必须在刀具进给程序中考虑法向位移的影响，并需要不断补偿。同时总结得出接触区抛光速度、抛光压力的分布规律，以Preston方程为依据，建立了材料去除模型。
3.基于MRT力矩伺服的气囊抛光实验样机的研制。进行了MRT结构设计及力矩测试实验，研制了气囊抛光工具系统，实现了气囊抛光过程中力/位分离同步控制。推导了位置空间内机床坐标、刀具坐标之间的关系。
4.为了进一步开展气囊抛光实验，搭建了气囊抛光系统硬件平台，建立了抛光力控制模型，设计了电流源、抛光力相关控制软件，并介绍了非球面工件基于MasterCAM软件生成数控代码的过程。
5.气囊抛光工艺实验及非球面工件气囊抛光实验。分析气囊压缩量、励磁电流、姿态角以及气囊转速等工艺参数对接触区特性影响规律。应用此种新型气囊抛光方法对实际抛物面工件进行气囊抛光，获得表面粗糙度Ra=29nm的光滑表面。
本文将磁流变液应用于力矩伺服装置，将其作为一种加载机构成功应用于非球面气囊抛光加工中，提出了一种基于MRT的新型气囊抛光方法，在国内外关于气囊抛光的研究中尚未见正式报道。实际应用表明，将MRT技术与气囊抛光技术融合，从根本上解决抛光过程中力/位耦合问题，显著提高了非球面工件加工的效率和精度，开辟了磁流变液（MRF）在超精密加工领域的新途径，拓宽了MRF这种智能材料的应用范围。
In recent years, with constantly understanding of Magnetorhelogical fluid (MRF)as wellasthe rapidly development in precision machining and manufacturing technology, as a newtype of smart material, MRF has attracted the interest of a large number of experts andscholars at home and abroad. Research on MRF devices and applications has a largeproportion in many related fields.Many scholars had used MRF as a working medium forpolishing, but its application to torque servo device used for bonnet polishing is seldomreported.
The study has been supported by the National Natural Science Foundation of Chinaunder grant No.50705044. Aspheric surface polishing is not easy to control as force andposition coupling and robot auxiliary bonnet polishing has poor rigidity. Anovelmethod ofbonnet polishing based on magnetorheological torque servo has been proposed on the basis ofthe previous work of members.It changes the loading mode while by adjusting the gasbaginternal pressure in the past. It provides proper polishing force for bonnet polishing systemusing MRT. It is easy to control. The process experimental study has been preceded in theself-developed bonnet polishing prototype and the results are better.
The main research contents, technical methods and conclusions are as follows:
1. Summarized the status and development of MRT devices and applications as well asbonnet polishing technique at home and abroad on the basis of investigation on relatedcontent. It presents the research contents of this paper through comprehensive analysis of thecharacteristics of magnetorheological effect and bonnet polishing method in the field ofpolishing aspheric surface.
2. The mechanism of polishing force and position coupling and the interactiondeformation among polishing film、abrasive and the part are analyzed on the basis of studying the traditional polishing theories and contact mechanics. The research results show that theposition of polishing tool is affected by the normal displacement between the bonnetpolishing tool and aspheric part. In order to guarantee the normal displacement has no effecton processing surface quality, it must be considered the influence of the displacement in thetool feed program and needs to keep compensation. The polishing speed and polishingpressure distribution in the contact area are deduced. According to Preston’s law, the materialremoval model has been established.
3. Development of the bonnet tool polishing experiment prototype based on MRT. Thestructure design of MRT and torque test has been launched. And the bonnet tool polishingsystem is developed. The problem of force-position coupling can be resolved. The relationbetween machine coordinate and tool coordinate in position space is deduced.
4. The bonnet polishing system hardware is built in order to further develop thepolishing experiment. The control model of the polishing force based on MRT is establishedwith the target of achieving the constant material removal rates. The related software of thecurrent source and polishing force is designed. The generation of CNC code of aspheric partis introduced based on MasterCAM.
5. Bonnet polishing process experiment and bonnet polishing of aspheric. The influencelaw on the process parameters as air compression, excitation current, attitude angle and airbagspeed in contact area characteristics is analyzed. Application of this novel polishing methodon polishing actual parabolicpart can get the smooth surface of Ra=29nm.
In short, MRF is used for torque servo system and successfully applied to bonnet toolpolishing of aspheric surface as loading mechanism. A novel method of bonnet polishing isproposed. Research about this kind of bonnet polishing method based on MRT has not beenformally reported.
Practice has proved that the fusion of the MRT technology and bonnet polishingtechnology can solute the polishing force-position coupling problem. It can significantlyimprove the efficiency and accuracy of the part. The original application of MRF in bonnetpolishing will further broaden the application field of this smart material.
引文
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