高效精密切削及其振动特性的研究
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摘要
高效精密切削加工是以高速加工技术为手段,以精密加工质量为目标,实现高效率、低成本和高质量三者有机统一的一种综合切削加工技术,是先进制造技术发展的主要方向之一。随着切削速度的提高,切削过程中的振动对生产效率、加工质量以及加工稳定性影响也随之增加,成为影响和制约高效精密切削技术发挥其优势的一个关键因素。本文以精密车削和高速铣削为背景,对高效精密加工中的切削力、切削系统的动态特性、切削振动及其稳定性以及加工表面形态等进行了系统的理论和实验研究,主要研究工作及其创新成果为:
首先,运用坐标变换方法,给出了包含刀具主偏角的斜角切削加工切削力的理论公式,在此基础上,利用微分法建立车刀刀尖圆弧和球头铣刀的切削力数学模型,其数值计算与有关实验表明,本研究建立的模型所预测的切削力与精密车削力和球头铣削力的变化趋势基本吻合,验证了该模型的有效性,并通过频谱分析技术探讨斜角加工中切削力变化的主要成因。
其次,利用实验模态分析方法研究了精密车床和高速加工中心的动态特性变化,特别是机床主轴连接刀柄系统(工件)前后的动态特性变化,以及刀具悬臂长度、夹紧力和刀具(工件)的装夹方式等对主轴动态特性的影响,从而系统深入地揭示出切削系统的动态特性,为实现切削系统的振动控制及其稳定性奠定了基础。
第三,针对高速精密切削系统结构和受力都比较复杂的特点,对空转条件下和高速切削过程中刀具和主轴的振动等进行检测并进行对比分析,首次定量地描述了在不同的工具材料、不同的切削用量等条件下刀具/主轴的振动变化规律,探讨了引起切削振动的内在原因及其与切削力之间的相互关系。
第四,研究了高速切削过程中自激振动机理、特性及其稳定性,探讨了机床系统的动态特性、切削过程的动力学参数和切削用量以及铣刀齿数对切削稳定性的影响,给出了不同条件下的切削系统稳定性图,进而提出了提高高速精密切削稳定性的基本方法与途径。
第五,利用非接触表面形貌仪对高速精密切削加工的表面粗糙度和表面三维形貌进行分析,研究了切削速度、进给量和切削深度对表面质量的影响变化规律,分析了高速精密切削过程中的刀具磨损形式及其机理,并探讨高速精密切削中降低表面粗糙度的切削用量匹配与优化方法,为高效精密切削加工生产中切削用量的选择与优化提供了参考依据。
本研究是国家自然科学基金项目——精密零件棱边的形成机理及其控制(№50275066)和国家十五科技攻关项目——高速加工工具系统的开发与应用(№2001BA205805/05)的组成部分之一,并得到江苏大学研究生科技创新基金项目的资助。
High efficiency precision cutting is one of the advanced machining technologies which possess the advantages of high efficiency and high precision. With the increase of machining speed, the influence of vibration in machining process on the efficiency, surface quality as well as the stability in machining is greatly increasing. So it becomes the important factor to limit the development and reasonable application of the high speed cutting technology. Therefore, based on the high precision turning and high speed milling, a systemically theoretical and experimental investigation on the cutting force, the dynamical characteristic of the cutting system, the vibrating and its stability, as well as the machining surface roughness and profile in high efficiency precision cutting is carried out for understanding and optimizing machining operations and upgrade their performance.
The extended oblique machining theory developed with conversion of coordinates in this research is used in understanding the mechanics underlying the high efficiency precision cutting. Based on this theory, the analytical models of cutting forces for nose turning and ball-end milling were developed respectively. Taking into account the effects of cutter nose, helix angle and depth of cut, the model predicts characteristic variation of cutting forces in a series of high-speed precision machining. The changing causes of the cutting force in oblique cutting experiments are discussed using the Spectrum analyses.
With the example of the super-precision and high speed machining centre, the influence of clamping force and the length of cutter(workpiece) on dynamic characteristics of different spindle/holder and cutters combination is analyzed. The dynamic characteristic of the spindle and cutter(workpiece) is compared with bare spindle's and theoretical value. It is shown that the spindle dynamic behavior can vary substantially due to effects of the structure coupling.
This thesis scrutinizes the vibrations in high speed precisions machining. Considering the complexity of the structure and the force in high speed precision machining system, the experiments of idling of spindle and high speed cutting are designed and carried out to investigate thoroughly the vibration of the spindle, cutter and workpiece involved in high speed precisions machining. A solid foundation was achieved from both theoretical and experimental methods in order to analyze the vibrations involved. The changing law of the vibration of cutter/spindle in different workpiece material and different cutting parameter is discussed quantificationally.
The stability of the linearized dynamic model is investigated using an analytical frequency domain method. The computation of the stability in both turning and milling are conduct to investigate the effect of machine tool dynamics and cutting parameter on the stability of the turning and ball-end milling processes. The effect of varying the clamping force and cantilever length on the stability is also investigated. Based on these observations, it is put forward that the increment of the stiffness and damping of the system is one of the basic and important ways to increase the stability of the machining system.
With the help of the profiling techniques, the influences of cutting condition and vibration on surface roughness in high speed precisions cutting are analyzed systematically through a series of cutting experiments. Explanations for the observed trends are given. The tool wear form and wear mechanism in high speed precisions cutting experiments are also analyzed. The potential application of studying result in process optimization is discussed, which can be used as beneficial refer in practical high speed cutting.
首先,运用坐标变换方法,给出了包含刀具主偏角的斜角切削加工切削力的理论公式,在此基础上,利用微分法建立车刀刀尖圆弧和球头铣刀的切削力数学模型,其数值计算与有关实验表明,本研究建立的模型所预测的切削力与精密车削力和球头铣削力的变化趋势基本吻合,验证了该模型的有效性,并通过频谱分析技术探讨斜角加工中切削力变化的主要成因。
其次,利用实验模态分析方法研究了精密车床和高速加工中心的动态特性变化,特别是机床主轴连接刀柄系统(工件)前后的动态特性变化,以及刀具悬臂长度、夹紧力和刀具(工件)的装夹方式等对主轴动态特性的影响,从而系统深入地揭示出切削系统的动态特性,为实现切削系统的振动控制及其稳定性奠定了基础。
第三,针对高速精密切削系统结构和受力都比较复杂的特点,对空转条件下和高速切削过程中刀具和主轴的振动等进行检测并进行对比分析,首次定量地描述了在不同的工具材料、不同的切削用量等条件下刀具/主轴的振动变化规律,探讨了引起切削振动的内在原因及其与切削力之间的相互关系。
第四,研究了高速切削过程中自激振动机理、特性及其稳定性,探讨了机床系统的动态特性、切削过程的动力学参数和切削用量以及铣刀齿数对切削稳定性的影响,给出了不同条件下的切削系统稳定性图,进而提出了提高高速精密切削稳定性的基本方法与途径。
第五,利用非接触表面形貌仪对高速精密切削加工的表面粗糙度和表面三维形貌进行分析,研究了切削速度、进给量和切削深度对表面质量的影响变化规律,分析了高速精密切削过程中的刀具磨损形式及其机理,并探讨高速精密切削中降低表面粗糙度的切削用量匹配与优化方法,为高效精密切削加工生产中切削用量的选择与优化提供了参考依据。
本研究是国家自然科学基金项目——精密零件棱边的形成机理及其控制(№50275066)和国家十五科技攻关项目——高速加工工具系统的开发与应用(№2001BA205805/05)的组成部分之一,并得到江苏大学研究生科技创新基金项目的资助。
High efficiency precision cutting is one of the advanced machining technologies which possess the advantages of high efficiency and high precision. With the increase of machining speed, the influence of vibration in machining process on the efficiency, surface quality as well as the stability in machining is greatly increasing. So it becomes the important factor to limit the development and reasonable application of the high speed cutting technology. Therefore, based on the high precision turning and high speed milling, a systemically theoretical and experimental investigation on the cutting force, the dynamical characteristic of the cutting system, the vibrating and its stability, as well as the machining surface roughness and profile in high efficiency precision cutting is carried out for understanding and optimizing machining operations and upgrade their performance.
The extended oblique machining theory developed with conversion of coordinates in this research is used in understanding the mechanics underlying the high efficiency precision cutting. Based on this theory, the analytical models of cutting forces for nose turning and ball-end milling were developed respectively. Taking into account the effects of cutter nose, helix angle and depth of cut, the model predicts characteristic variation of cutting forces in a series of high-speed precision machining. The changing causes of the cutting force in oblique cutting experiments are discussed using the Spectrum analyses.
With the example of the super-precision and high speed machining centre, the influence of clamping force and the length of cutter(workpiece) on dynamic characteristics of different spindle/holder and cutters combination is analyzed. The dynamic characteristic of the spindle and cutter(workpiece) is compared with bare spindle's and theoretical value. It is shown that the spindle dynamic behavior can vary substantially due to effects of the structure coupling.
This thesis scrutinizes the vibrations in high speed precisions machining. Considering the complexity of the structure and the force in high speed precision machining system, the experiments of idling of spindle and high speed cutting are designed and carried out to investigate thoroughly the vibration of the spindle, cutter and workpiece involved in high speed precisions machining. A solid foundation was achieved from both theoretical and experimental methods in order to analyze the vibrations involved. The changing law of the vibration of cutter/spindle in different workpiece material and different cutting parameter is discussed quantificationally.
The stability of the linearized dynamic model is investigated using an analytical frequency domain method. The computation of the stability in both turning and milling are conduct to investigate the effect of machine tool dynamics and cutting parameter on the stability of the turning and ball-end milling processes. The effect of varying the clamping force and cantilever length on the stability is also investigated. Based on these observations, it is put forward that the increment of the stiffness and damping of the system is one of the basic and important ways to increase the stability of the machining system.
With the help of the profiling techniques, the influences of cutting condition and vibration on surface roughness in high speed precisions cutting are analyzed systematically through a series of cutting experiments. Explanations for the observed trends are given. The tool wear form and wear mechanism in high speed precisions cutting experiments are also analyzed. The potential application of studying result in process optimization is discussed, which can be used as beneficial refer in practical high speed cutting.
引文
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