高速陶瓷电主轴的设计与制造关键技术研究
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摘要
电主轴单元是一种直接依赖于高速精密轴承技术、高速电机与驱动技术、油气润滑与冷却技术、精密制造与装配技术等关键技术及相关配套技术的高度机电一体化的数控机床关键功能部件。利用高性能结构陶瓷作为高速主轴轴承及主轴材料研制开发陶瓷电主轴单元,可以充分发挥陶瓷材料密度小、耐高温、耐磨损、高强度等优良性能,极大地减少主轴部件高速旋转的离心力和惯性力,提高主轴单元的刚度和回转精度,使我国数控机床及其主轴功能部件的产品档次明显提高。
本文以提高陶瓷电主轴的性能并实现其在数控机床中的应用为目标,围绕高速陶瓷电主轴单元的设计与制造关键技术问题进行了深入系统的研究。
(1)创新性的设计并制造了一种无内圈式陶瓷电主轴。该陶瓷电主轴的支撑轴承为无内圈式热压氮化硅全陶瓷球轴承,转子轴采用氧化锆陶瓷烧结制成,轴上加工有轴承内滚道。通过对陶瓷电主轴关键技术的研究,进行了陶瓷轴承内部结构参数优化和陶瓷电主轴总体结构设计,实现了高速陶瓷电主轴单元的精密装配。
(2)首次将陶瓷材料应用于主轴电机转子轴芯,并对陶瓷主轴电机主要设计参数进行了设计确定。建立了主轴电机的数学模型,并对其直接转矩控制进行了仿真分析,实现了基于PMAC的陶瓷电主轴的直接转矩控制。
(3)研究了陶瓷主轴零件的制备工艺,实现了高强、高韧陶瓷主轴的近净尺寸烧结。研究了陶瓷材料的磨削机理、磨削力、磨削表面质量控制方法及相应工艺参数的优化问题,实现了陶瓷主轴及陶瓷球轴承的精密加工,陶瓷滚道表面粗糙度Ra<0.05μm,滚道轮廓度Pt接近1μm,无内圈式陶瓷主轴-轴承单元的精度达到P4级轴承检测标准。
(4)对所研制的无内圈式陶瓷电主轴样机进行综合性能试验与分析,试验结果表明,其最高转速达到30000r/min,最大功率达到15kW,主轴静态精度≤1μm,在最佳润滑条件和最佳预紧力条件下,陶瓷主轴系统的径向静刚度可达322N/μm,空载振动<0.8mm/s,空载温升<10℃。已应用于数控机床,且运行稳定可靠,精度保持性好。
通过本文的研究,不仅为数控机床高速无内圈式陶瓷电主轴的设计开发提供了主要理论依据和技术支持,还在陶瓷电主轴结构设计与优化、陶瓷零部件设计与加工、主轴电机设计与驱动控制等方面的基础理论和关键技术上取得了具有自主知识产权的原创成果,从而推动了高速陶瓷电主轴单元在数控机床上应用与发展。
High performance spindle system is one of the key function units of NC machine tools. Motorized spindle is the main form of high-speed spindle system, which integrates many key technologies such as high-speed precision bearings, high-speed motor and driving, oil-air lubrication and cooling, precision manufacturing and assembling, and some other related supporting technologies. In this research, a high speed ceramic motorized spindle equipped with high-performance structural ceramic shaft and bearings is designed and developed. Because of engineering ceramics' extraordinary physical properties such as high hardness, low thermal expansion, light weight, abrasion resistant and good chemical and thermal stability, it can reduce the high-speed rotational centrifugal force and inertia force and increase the stiffness and rotation accuracy of spindle-bearing system greatly, so as to accommodate very well the high-speed and precision requirements of spindle system. In addition, it can reduce friction and decrease the temperature response, accordingly effectively reduce the energy consumption and save resources. Development of ceramic motorized spindle can improve the performance and quality of the spindle system and NC machine tool significantly.
In this paper, in order to improve the performance of ceramic motorized spindle and achieve its application in NC machine tools, the following key technologies of ceramic motorized spindle in process of design and manufacturing are researched.
(1) Innovative high speed ceramic motorized spindle with a bearing without inner rings is designed and manufactured. The bearings are a kind of hot isostatically pressed silicon nitride (HIPSN) fully-ceramic ball bearings, whose rotor shaft is made from yttria partially stabilized zirconia (Y-PSZ), on which the outer race is designed. Ceramic ball bearings'kinematics, dynamics, failure mechanism and life prediction and other basic theoretical problems are researched. Internal structure parameters of ceramic bearings and the overall structure of ceramic motorized spindle are designed and optimized. It achieves an assembly of high-speed ceramic motorized spindle with high precision.
(2) The ceramic material is used in the motor rotor shaft of spindle. Through creating motor model of the ceramic spindle, primary design parameters of ceramic spindle motor are optimized. Direct torque control system of ceramic motorized spindle based on PMAC is designed and researched. The theoretical analysis and simulation research on it are finished.
(3) The near-net size sintered process of ceramic parts is researched. High-strength and high toughness ceramic spindle blank parts are sintered successfully. The grinding mechanism, grinding force, grinding surface quality control methods and the corresponding process parameters optimization of ceramic grinding are studied. The high-precision machining technologies of ceramic balls, ceramic rings and ceramic shafts are achieved. The surface roughness of ceramic bearing race is less than0.05μm. The machining accuracy of ceramic spindle shafts and ceramic bearing rings reach grade P4of the testing standard for precision of bearing components.
(4) Performance test and analysis of the developed ceramic motorized spindle are finished. The test results show that the maximum speed achieves30000r/min, the maximum power achieves15kW, radial runout of shaft is less than μm, in the condition of best lubrication and appropriate preload, radial rigidity of the ceramic spindle system achieves322N/μm, no-load vibration is less than0.8mm/s, no-load temperature rise is less than10℃. Ceramic motorized spindle has been applied in NC machine tools successfully.
This study not only provides the theoretical basis and technical support for design and development of ceramic motorized spindle without inner rings on high-speed NC machine tools, but also obtains original achievements with independent intellectual property rights on basic theories and key technologies of structural design and optimization of ceramic spindle, design and processing of ceramic parts, spindle motor design and drive control, and so on., accordingly promotes the application and development of high-speed ceramic motorized spindle in NC machine tools.
本文以提高陶瓷电主轴的性能并实现其在数控机床中的应用为目标,围绕高速陶瓷电主轴单元的设计与制造关键技术问题进行了深入系统的研究。
(1)创新性的设计并制造了一种无内圈式陶瓷电主轴。该陶瓷电主轴的支撑轴承为无内圈式热压氮化硅全陶瓷球轴承,转子轴采用氧化锆陶瓷烧结制成,轴上加工有轴承内滚道。通过对陶瓷电主轴关键技术的研究,进行了陶瓷轴承内部结构参数优化和陶瓷电主轴总体结构设计,实现了高速陶瓷电主轴单元的精密装配。
(2)首次将陶瓷材料应用于主轴电机转子轴芯,并对陶瓷主轴电机主要设计参数进行了设计确定。建立了主轴电机的数学模型,并对其直接转矩控制进行了仿真分析,实现了基于PMAC的陶瓷电主轴的直接转矩控制。
(3)研究了陶瓷主轴零件的制备工艺,实现了高强、高韧陶瓷主轴的近净尺寸烧结。研究了陶瓷材料的磨削机理、磨削力、磨削表面质量控制方法及相应工艺参数的优化问题,实现了陶瓷主轴及陶瓷球轴承的精密加工,陶瓷滚道表面粗糙度Ra<0.05μm,滚道轮廓度Pt接近1μm,无内圈式陶瓷主轴-轴承单元的精度达到P4级轴承检测标准。
(4)对所研制的无内圈式陶瓷电主轴样机进行综合性能试验与分析,试验结果表明,其最高转速达到30000r/min,最大功率达到15kW,主轴静态精度≤1μm,在最佳润滑条件和最佳预紧力条件下,陶瓷主轴系统的径向静刚度可达322N/μm,空载振动<0.8mm/s,空载温升<10℃。已应用于数控机床,且运行稳定可靠,精度保持性好。
通过本文的研究,不仅为数控机床高速无内圈式陶瓷电主轴的设计开发提供了主要理论依据和技术支持,还在陶瓷电主轴结构设计与优化、陶瓷零部件设计与加工、主轴电机设计与驱动控制等方面的基础理论和关键技术上取得了具有自主知识产权的原创成果,从而推动了高速陶瓷电主轴单元在数控机床上应用与发展。
High performance spindle system is one of the key function units of NC machine tools. Motorized spindle is the main form of high-speed spindle system, which integrates many key technologies such as high-speed precision bearings, high-speed motor and driving, oil-air lubrication and cooling, precision manufacturing and assembling, and some other related supporting technologies. In this research, a high speed ceramic motorized spindle equipped with high-performance structural ceramic shaft and bearings is designed and developed. Because of engineering ceramics' extraordinary physical properties such as high hardness, low thermal expansion, light weight, abrasion resistant and good chemical and thermal stability, it can reduce the high-speed rotational centrifugal force and inertia force and increase the stiffness and rotation accuracy of spindle-bearing system greatly, so as to accommodate very well the high-speed and precision requirements of spindle system. In addition, it can reduce friction and decrease the temperature response, accordingly effectively reduce the energy consumption and save resources. Development of ceramic motorized spindle can improve the performance and quality of the spindle system and NC machine tool significantly.
In this paper, in order to improve the performance of ceramic motorized spindle and achieve its application in NC machine tools, the following key technologies of ceramic motorized spindle in process of design and manufacturing are researched.
(1) Innovative high speed ceramic motorized spindle with a bearing without inner rings is designed and manufactured. The bearings are a kind of hot isostatically pressed silicon nitride (HIPSN) fully-ceramic ball bearings, whose rotor shaft is made from yttria partially stabilized zirconia (Y-PSZ), on which the outer race is designed. Ceramic ball bearings'kinematics, dynamics, failure mechanism and life prediction and other basic theoretical problems are researched. Internal structure parameters of ceramic bearings and the overall structure of ceramic motorized spindle are designed and optimized. It achieves an assembly of high-speed ceramic motorized spindle with high precision.
(2) The ceramic material is used in the motor rotor shaft of spindle. Through creating motor model of the ceramic spindle, primary design parameters of ceramic spindle motor are optimized. Direct torque control system of ceramic motorized spindle based on PMAC is designed and researched. The theoretical analysis and simulation research on it are finished.
(3) The near-net size sintered process of ceramic parts is researched. High-strength and high toughness ceramic spindle blank parts are sintered successfully. The grinding mechanism, grinding force, grinding surface quality control methods and the corresponding process parameters optimization of ceramic grinding are studied. The high-precision machining technologies of ceramic balls, ceramic rings and ceramic shafts are achieved. The surface roughness of ceramic bearing race is less than0.05μm. The machining accuracy of ceramic spindle shafts and ceramic bearing rings reach grade P4of the testing standard for precision of bearing components.
(4) Performance test and analysis of the developed ceramic motorized spindle are finished. The test results show that the maximum speed achieves30000r/min, the maximum power achieves15kW, radial runout of shaft is less than μm, in the condition of best lubrication and appropriate preload, radial rigidity of the ceramic spindle system achieves322N/μm, no-load vibration is less than0.8mm/s, no-load temperature rise is less than10℃. Ceramic motorized spindle has been applied in NC machine tools successfully.
This study not only provides the theoretical basis and technical support for design and development of ceramic motorized spindle without inner rings on high-speed NC machine tools, but also obtains original achievements with independent intellectual property rights on basic theories and key technologies of structural design and optimization of ceramic spindle, design and processing of ceramic parts, spindle motor design and drive control, and so on., accordingly promotes the application and development of high-speed ceramic motorized spindle in NC machine tools.
引文
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