大型不规则薄壁零件测量—加工一体化制造方法与技术
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摘要
在我国航空航天、运载、国防等重大工程领域中,出现了一批必须满足其高性能要求的大型不规则薄壁零件,如火箭发动机喷管、火箭推进剂共底构件、火箭燃料贮箱壁板等。这类零部件具有几何尺寸大、形状复杂、结构刚度低、材料难加工等制造特点,易在半精加工阶段产生较大的结构变形。若仅按照原始设计尺寸或模型进行常规数控加工,无法加工出满足几何精度和性能要求的零件。本文以我国大型／重载液体火箭发动机的研制为工程背景,依托国家自然科学基金重点基金(No.50835001)、装备预研基金重点基金(No.9140x×××××××××x0902)和航天科技集团委托项目,针对大型不规则薄壁零件加工精度难以保证的问题,开展高效、精密数字化加工方法与关键技术的研究。
针对大型不规则薄壁零件尺寸误差或结构变形导致实际加工曲面与设计模型不一致的加工难题,提出一种基准关联约束的精加工目标曲面生成方法。基于E.Cartan活动标架和曲面相伴理论,利用在机实测的几何参数数据,在分析被测面、基准面及加工目标曲面的空间位姿关系基础上,研究精加工目标曲面建模技术及曲面生成算法,再设计出精加工目标曲面。
为提高大型复杂几何廓形的测量速度与精度,提出一种基于截面线法的点激光快速、精密扫描测量方法。研究复杂曲面几何信息提取技术、激光三角法曲面测量误差预测技术。针对等步长测量方案易丢失关键几何信息的问题,研究基于曲面局部曲率特征的测量控制步长优化控制技术,进而实现测点在被测曲面上的自适应分布。对于模型已知曲面,利用设计模型规划出传感器的采样控制点；对于模型未知曲面,在已测坐标的基础上利用混合预估法和二次形函数优化计算进给步长和测量行距。根据激光传感器位移测量误差与曲面几何特征的强关联性,量化分析了入射角度对测量精度的影响规律。
针对不锈钢材料加工效率低、易切削振动等问题,研究其铣削过程的动力学建模与稳定性性预测。建立考虑刀具偏心的三维稳态切削力力学模型和“主轴-刀具-零件”自由度加工动力学模型；基于材料本构关系和斜切机理,构建一种面向参数化铣刀的通用三维稳态切削力预报模型；利用高次谐波影响的多频法对盘铣刀铣槽加工进行切削稳定性预测,并根据稳定性叶瓣图优化切削参数。
针对液体火箭发动机喷管直槽冷却通道原有的卧式仿形加工方式存在的零件胀形大、自动化程度差、产品合格率低等问题,发明了喷管直槽冷却通道的立式对称加工方法。设计了喷管直槽冷却通道数字化铣槽加工方案,研制出喷管立式装夹高刚度工装卡具,开发出在零件一次装夹下实现其几何参数在机测量、铣槽加工等多工位自动化操作的加工控制系统,研制出双主轴、双立柱结构的铣槽加工专用装备。
所研究的测量-加工一体化制造方法和高效率、高可靠性的专用加工装备成功应用于新一代液体火箭发动机喷管铣槽加工,为我国航天事业的发展做出了积极贡献。
There are a number of large irregular thin-walled parts with high-performance machining requirements in national major projects, including aerospace, carrying and defense. Rocket nozzles, rocket propellant isolation layer structure and rocket fuel tank panel are three typical parts, which share some common manufacturing features, such as large size, complex shape, low structural stiffness, difficult-to-machine materials, etc. As a result, the structural deformation error is easily caused at semi-finishing stage, which is much larger than the tolerance. If the codes in accordance with the original design model are directly adopted in NC machining, the machined parts can not satisfy the accuracy and performance requirements. Therefore, it is very difficult to machine those parts. The dissertation is carried out according to the large/heavy liquid rocket engine development project from China Aerospace Science and Technology Corporation. The subject has also been funded by Natural Science Foundation of China (key program grant No.50835001) and Advanced Research Foundation (key program grant No.9140××××××××××××0902).In this dissertation, the machining problems of large irregular thin-walled parts are analyzed. An efficient and precision digital machining theory and some key technologies are researched.
A troublesome problem arises for the large irregular thin-walled parts. It is the actual target surface which is inconsistent with the design model. To obtain the finishing target surface, a novel surface generation method is developed taking dimension error or structure deformation into consideration. It can satisfy the digital machining method which integrates measurement, surface redesign and machining. The spatial pose of measurable reference surface, datum surface and target surface are initially analyzed. A modeling technique for target surface redesign is developed based on E.Cartan moving frame theory and surface accompanied theory. And a computing method for surface redesign is then researched utilizing the measured data of geometrical parameters. On the base of the analysis mentioned above, the finishing target surface can be redesigned in accordance with performance constrains.
In order to imrpove the coordinate extracting speed and accuracy of large complex geometric profile, a fast and precision non-contact laser scanning method is developed based on iso-planar principle. Both the geometric information extraction technology for irregular surface with four sides and the measuring error prediction of laser triangulation method are researched. To avoid losing key geometric information as equal step strategy, the calculation of measuring control step is expanded from2D space to3D space. Further, coordinate points are adaptively distributed according to curvature characteristics. Sampling control points are planned using design model of model-known surface. But for the model-unknown surface, besides the measured information, a hybrid extrapolation method and a quadratic function are essential for optimizing feeding step and side interval. In the following, the impact of incident angle on measurement accuracy is quantitatively analyzed, which is on the base of strong correlation of displacement detection error and surface geometric features.
The milling dynamics process is modeled and the stablility is predicted against low machining efficincy and chatter of stainless steel material. A mechanics model to predict three-dimensional cutting forces with runout effect is developed, as well as a two-degree-of-freedom milling dynamics model of'spindle-cutter-workpiece'system is also established. The present cutting force models mainly focus on some special end mills. Based on oblique mechanism and material constitutive relations, a general3D steady-state cutting forces model for parameterized mills is formulated. Then, the stability is predicted using multi-frequency method which takes high harmonics effect into account. As a result, cutting parameters can be optimized according to stability lobe.
To solve the problems of the existing copying horizontal milling method for liquid rocket engine nozzle, such as bulging uneven, process dispersion, low machining efficiency and etc, a vertical machining method for straight cooling channel of rocket nozzle is invented in this dissertation. The digital slot milling strategy is designed for rocket nozzle. A high stiffness fixture is developed for vertical clamping of nozzle. Further, a multi-stage machining system is developed. Geometry parameters measurement and slot milling can be automatically accomplished under the condition of one-time setup. Finaly, a special machine with dual-spindle and double-column structure for slot milling is manufactured.
The proposed measurement-machining integrated manufacturing method and the special digital machining equipment with high efficiency and high reliability has been successfully applied to the new generation of liquid rocket engine nozzle, which has made a positive contribution to the development of China's aerospace industry.
针对大型不规则薄壁零件尺寸误差或结构变形导致实际加工曲面与设计模型不一致的加工难题,提出一种基准关联约束的精加工目标曲面生成方法。基于E.Cartan活动标架和曲面相伴理论,利用在机实测的几何参数数据,在分析被测面、基准面及加工目标曲面的空间位姿关系基础上,研究精加工目标曲面建模技术及曲面生成算法,再设计出精加工目标曲面。
为提高大型复杂几何廓形的测量速度与精度,提出一种基于截面线法的点激光快速、精密扫描测量方法。研究复杂曲面几何信息提取技术、激光三角法曲面测量误差预测技术。针对等步长测量方案易丢失关键几何信息的问题,研究基于曲面局部曲率特征的测量控制步长优化控制技术,进而实现测点在被测曲面上的自适应分布。对于模型已知曲面,利用设计模型规划出传感器的采样控制点；对于模型未知曲面,在已测坐标的基础上利用混合预估法和二次形函数优化计算进给步长和测量行距。根据激光传感器位移测量误差与曲面几何特征的强关联性,量化分析了入射角度对测量精度的影响规律。
针对不锈钢材料加工效率低、易切削振动等问题,研究其铣削过程的动力学建模与稳定性性预测。建立考虑刀具偏心的三维稳态切削力力学模型和“主轴-刀具-零件”自由度加工动力学模型；基于材料本构关系和斜切机理,构建一种面向参数化铣刀的通用三维稳态切削力预报模型；利用高次谐波影响的多频法对盘铣刀铣槽加工进行切削稳定性预测,并根据稳定性叶瓣图优化切削参数。
针对液体火箭发动机喷管直槽冷却通道原有的卧式仿形加工方式存在的零件胀形大、自动化程度差、产品合格率低等问题,发明了喷管直槽冷却通道的立式对称加工方法。设计了喷管直槽冷却通道数字化铣槽加工方案,研制出喷管立式装夹高刚度工装卡具,开发出在零件一次装夹下实现其几何参数在机测量、铣槽加工等多工位自动化操作的加工控制系统,研制出双主轴、双立柱结构的铣槽加工专用装备。
所研究的测量-加工一体化制造方法和高效率、高可靠性的专用加工装备成功应用于新一代液体火箭发动机喷管铣槽加工,为我国航天事业的发展做出了积极贡献。
There are a number of large irregular thin-walled parts with high-performance machining requirements in national major projects, including aerospace, carrying and defense. Rocket nozzles, rocket propellant isolation layer structure and rocket fuel tank panel are three typical parts, which share some common manufacturing features, such as large size, complex shape, low structural stiffness, difficult-to-machine materials, etc. As a result, the structural deformation error is easily caused at semi-finishing stage, which is much larger than the tolerance. If the codes in accordance with the original design model are directly adopted in NC machining, the machined parts can not satisfy the accuracy and performance requirements. Therefore, it is very difficult to machine those parts. The dissertation is carried out according to the large/heavy liquid rocket engine development project from China Aerospace Science and Technology Corporation. The subject has also been funded by Natural Science Foundation of China (key program grant No.50835001) and Advanced Research Foundation (key program grant No.9140××××××××××××0902).In this dissertation, the machining problems of large irregular thin-walled parts are analyzed. An efficient and precision digital machining theory and some key technologies are researched.
A troublesome problem arises for the large irregular thin-walled parts. It is the actual target surface which is inconsistent with the design model. To obtain the finishing target surface, a novel surface generation method is developed taking dimension error or structure deformation into consideration. It can satisfy the digital machining method which integrates measurement, surface redesign and machining. The spatial pose of measurable reference surface, datum surface and target surface are initially analyzed. A modeling technique for target surface redesign is developed based on E.Cartan moving frame theory and surface accompanied theory. And a computing method for surface redesign is then researched utilizing the measured data of geometrical parameters. On the base of the analysis mentioned above, the finishing target surface can be redesigned in accordance with performance constrains.
In order to imrpove the coordinate extracting speed and accuracy of large complex geometric profile, a fast and precision non-contact laser scanning method is developed based on iso-planar principle. Both the geometric information extraction technology for irregular surface with four sides and the measuring error prediction of laser triangulation method are researched. To avoid losing key geometric information as equal step strategy, the calculation of measuring control step is expanded from2D space to3D space. Further, coordinate points are adaptively distributed according to curvature characteristics. Sampling control points are planned using design model of model-known surface. But for the model-unknown surface, besides the measured information, a hybrid extrapolation method and a quadratic function are essential for optimizing feeding step and side interval. In the following, the impact of incident angle on measurement accuracy is quantitatively analyzed, which is on the base of strong correlation of displacement detection error and surface geometric features.
The milling dynamics process is modeled and the stablility is predicted against low machining efficincy and chatter of stainless steel material. A mechanics model to predict three-dimensional cutting forces with runout effect is developed, as well as a two-degree-of-freedom milling dynamics model of'spindle-cutter-workpiece'system is also established. The present cutting force models mainly focus on some special end mills. Based on oblique mechanism and material constitutive relations, a general3D steady-state cutting forces model for parameterized mills is formulated. Then, the stability is predicted using multi-frequency method which takes high harmonics effect into account. As a result, cutting parameters can be optimized according to stability lobe.
To solve the problems of the existing copying horizontal milling method for liquid rocket engine nozzle, such as bulging uneven, process dispersion, low machining efficiency and etc, a vertical machining method for straight cooling channel of rocket nozzle is invented in this dissertation. The digital slot milling strategy is designed for rocket nozzle. A high stiffness fixture is developed for vertical clamping of nozzle. Further, a multi-stage machining system is developed. Geometry parameters measurement and slot milling can be automatically accomplished under the condition of one-time setup. Finaly, a special machine with dual-spindle and double-column structure for slot milling is manufactured.
The proposed measurement-machining integrated manufacturing method and the special digital machining equipment with high efficiency and high reliability has been successfully applied to the new generation of liquid rocket engine nozzle, which has made a positive contribution to the development of China's aerospace industry.
引文
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