深孔加工中振动产生原因以及减振方法研究
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摘要
深孔钻削加工中，存在由机床本身产生的或通过地基传来的自由振动，由不平衡作用等引起的强迫振动，还有工件和深孔钻之间经常发生的强烈颤振，前两类振动在试制阶段就能找到必要的解决办法并消除掉，但对于颤振除了减少金属切削率很难找到其它补救办法，而且颤振降低加工质量，降低刀具和机床的使用寿命，所以对颤振的研究具有一定的实际意义。电流变液是一种能在外加电场作用下实现流变特性变化的可控流体，其粘度、屈服应力和剪切模量在外加电场下毫秒内会急剧增大，而且在撤除外加电场后又能瞬时恢复至原来的状态，因此其在振动控制方面有着潜在的应用前景。
针对深孔钻削加工中的颤振问题，本文提出利用电流变液来抑制颤振的发生。首先分析了深孔钻削过程中的振动情况以及颤振产生的原因，其中再生型颤振被证明是最主要的自激振动机理，在此基础上研究了深孔钻削过程的动力学模型，得到其运动微分方程及颤振发生时的动态钻削力计算公式。其次分析了电流变液的机理和电流变液减振器的原理，设计了应用于深孔机床的减振器，并研究了理论模型，最后得到其应用于深孔机床的动力学模型及动力学方程，利用Matlab中的Simulink组件对动力学方程进行了仿真，仿真表明减振器对颤振有很好的抑制作用。最后通过由3YD34型压电加速度计为测振元件的振动监测系统对卧式Z8016的深孔机床钻削过程进行了监测，采集了机床平稳钻削、发生颤振和安装减振器后的振动信号，对比分析三种信号的特点，结果证明减振器对深孔钻削的颤振有一定的抑制效果。
In deep hole drilling, free vibration is generated by the machine itselfor through the ground, and forced vibration caused by the imbalance, as wellas the frequent strong chatter between the workpiece and the deep hole drilling.The first two kinds of vibration will be able to find the necessary solutionsand eliminated in the trial stage, but for the chatter it is difficult to findother way except for reducing metal removal rate. The processing quality ofchatter, tool and machine life are reduced by the chatter. so the research ofchatter is practical and significant. ER fluid is a controllable fluid whichcan realize the changes of rheological properties. In an applied electric field,the viscosity, yield stress and shear modulus increase sharply withinmilliseconds. Removed the applied electric field, the fluid can recover to theoriginal state instantly. so it has a potential application in vibration control.
For the chatter problem in deep hole drilling, we propose to suppress thechatter by using the ER fluid. First, analyzing the vibration of deep holedrilling process and the causes of chatter, we find regenerative chatter isproved to be the most important mechanism of self-excited vibration. We researchthe dynamic model of deep-hole drilling process and obtain the differentialequations of motion and the formula of dynamic drilling force when chatter occurs.Second, analyzing the mechanism of ER and the principle of ERF damper, we designa damper used in deep hole machine, study the theory model, and get the dynamicmodel and dynamic equation. Finally the dynamic equation is simulated by Simulink components of Matlab, the simulation shows that the ERF damper takes good effect.Third, monitoring the vibration of drilling process of the horizontal deep holemachine Z8016 by 3YD34 piezoelectric accelerometer components for the vibrationmonitoring system, collecting the signal of a steady drilling, the occurrenceof chatter and vibration of the machine which was installed damper. Comparedthree types of signals, the results show that the damper has a good effect onthe chatter.
针对深孔钻削加工中的颤振问题，本文提出利用电流变液来抑制颤振的发生。首先分析了深孔钻削过程中的振动情况以及颤振产生的原因，其中再生型颤振被证明是最主要的自激振动机理，在此基础上研究了深孔钻削过程的动力学模型，得到其运动微分方程及颤振发生时的动态钻削力计算公式。其次分析了电流变液的机理和电流变液减振器的原理，设计了应用于深孔机床的减振器，并研究了理论模型，最后得到其应用于深孔机床的动力学模型及动力学方程，利用Matlab中的Simulink组件对动力学方程进行了仿真，仿真表明减振器对颤振有很好的抑制作用。最后通过由3YD34型压电加速度计为测振元件的振动监测系统对卧式Z8016的深孔机床钻削过程进行了监测，采集了机床平稳钻削、发生颤振和安装减振器后的振动信号，对比分析三种信号的特点，结果证明减振器对深孔钻削的颤振有一定的抑制效果。
In deep hole drilling, free vibration is generated by the machine itselfor through the ground, and forced vibration caused by the imbalance, as wellas the frequent strong chatter between the workpiece and the deep hole drilling.The first two kinds of vibration will be able to find the necessary solutionsand eliminated in the trial stage, but for the chatter it is difficult to findother way except for reducing metal removal rate. The processing quality ofchatter, tool and machine life are reduced by the chatter. so the research ofchatter is practical and significant. ER fluid is a controllable fluid whichcan realize the changes of rheological properties. In an applied electric field,the viscosity, yield stress and shear modulus increase sharply withinmilliseconds. Removed the applied electric field, the fluid can recover to theoriginal state instantly. so it has a potential application in vibration control.
For the chatter problem in deep hole drilling, we propose to suppress thechatter by using the ER fluid. First, analyzing the vibration of deep holedrilling process and the causes of chatter, we find regenerative chatter isproved to be the most important mechanism of self-excited vibration. We researchthe dynamic model of deep-hole drilling process and obtain the differentialequations of motion and the formula of dynamic drilling force when chatter occurs.Second, analyzing the mechanism of ER and the principle of ERF damper, we designa damper used in deep hole machine, study the theory model, and get the dynamicmodel and dynamic equation. Finally the dynamic equation is simulated by Simulink components of Matlab, the simulation shows that the ERF damper takes good effect.Third, monitoring the vibration of drilling process of the horizontal deep holemachine Z8016 by 3YD34 piezoelectric accelerometer components for the vibrationmonitoring system, collecting the signal of a steady drilling, the occurrenceof chatter and vibration of the machine which was installed damper. Comparedthree types of signals, the results show that the damper has a good effect onthe chatter.
引文
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[2]王峻. 20世纪深孔加工技术的兴衰及新突破——介绍SIED深孔加工集成技术.机械管理开发.2004，（79）:1～3.
[3]章宗诚．日本三菱公司新型高阻尼抗振FSCL型镗杆．工具技术.2000，（5）:40.
[4] Min Wang, Renyuan Fei. Chatter suppression based on nonlinear vibrationcharacteristic of electrorheological fluids. International Journal of MachineTools & Manufacture.1999,39:1925～1934.
[5]于骏一，周晓勤，包善斐.切削颤振的预报控制.振动工程学报，1990，3（l）:72～78.
[6]于骏一，周晓勤.切削颇振的预报控制.中国机械工程，1999，10（9）:1028～1032.
[7]曲兴田，吴博达，刘笑羽，王永彬.车削加工中心切削颇振的预报控制.吉林工业大学学报，1998，28（2）:24～27.
[8]徐飙.结构振动控制理论与应用现状分析.山西建筑，2009，35（19）:59～60.
[9]李浩久,强文博,师小燕.结构振动控制的发展和现状.四川建筑，2009,29（3）:104～106.
[10]黄大宇.结构振动控制的研究进展与展望.中原工学院学报，2009，20（4）:43～45.
[11]陈海卫.振动控制技术的发展及存在问题的探讨.福建建设科技，2010，（1）:32～33.
[12]赵有泽.半主动控制的国内外研究现状.山西建筑，2010，36（17）:50～51.
[13] S.A.托贝斯.机床振动学.北京：机械工业出版社，1980:135～136.
[14]袁忠于.深孔钻削加工的振动分析及仿真.兰州：兰州理工大学，2005.
[15]徐兴强.机床切削颤振系统与在线监测的仿真研究.辽宁：辽宁工程技术大学，2005.
[16]冯之敬.机械制造工程原理.北京：清华大学出版社，2006:261～262.
[17]王峻.现代深孔加工技.哈尔滨：哈尔并工业大学出版社，2005:26～33.
[18] H.Block,J.P.Kelly. Electro-rheology.Journal of Physics D: AppliedPhysics.1988,21.12:1661～1667.
[19] B.Chadwick,M.Nowak. Controllable fluid gripping devices. US Patent 5970581,1999.
[20] Y.L.Xu,W.L.Qu,J.M.Ko.Seismic response control of frame structures usingmagnetorheological/electrorheological dampers.Earthquake Engineering andStructural Dynamics.2000,29.5:557～575.
[21] K.Bohon,S.Krause. An electrorheological fluid and siloxane gel basedelectromechanical actuator : Working toward an artificial muscle. Journal ofpolymer science. Part B. Polymer physics.1998,36.6:1091～1094.
[22] J.Starkovich,E.Shtarkman.Spacecraft deployment mechanism damper .Eur.Patent EP0872665,1998.
[23] J.B.Lu,Q.S Yan.,H Tian.,L.Y Kong. Polishing properties of tiny grindingwheel based on Fe3O4 electrorheological fluid. Journal of Materials ProcessingTechnology.2009,209:4954～4957.
[24]魏宸官.电流变技术[M].北京:北京理工大学出版社,2000.
[25] K.Di,Y.Zhu,X.Yang,C.Li.Electrorheological behavior of copperphthalocyanine-doped mesoporous TiO2 suspensions. Journal of Colloid andInterface Science.2006,294：499～503.
[26] A. Lengálová, V.Pavl?nek, P. Sáha,O. Quadrat, J. Stejskal. The effect ofdispersed particle size and shape on the electrorheological behaviour ofsuspensions. Colloids and Surfaces A: Physicochem. Eng. Aspects.2003,227:1～8.
[27] K.O. Havelka,F.E. Filisko. Progress in Electrorheology. New York: PlenumPress,1995:3.
[28] Y. Komoda, N. Sakai. Photoelectrorheological Phenomena Involving TiO2Particle Suspensions.Langmuir,1998,14(5):1081～1091.
[29] P. Atten, J-N. Foulc, N.J. Felici. A conduction model of theelectrorheological effect. International Journal of Modern Physics B,1994,8(20):2731～2745.
[30] Choi C S,Park S J,et al.Carbon nanotube/polyaniline nanocomposites andtheir electrorheological characteristics under an applied electricfield[J].Current Appl Phys, 2007, 7:352.
[31] Hyon-Jee Lee, Byung Doo Chin,et al.Surfactant effect on the stability andelectrorheological properties of polyaniline particle suspension[J]. J CollInterf Sci, 1998,206:424.
[32] Zhang Shengbin, William T Winter. Water-activated cellu-lose-basedelectrorheological fluids[J]. Cellulose, 2005,12:135.
[33]龚烈航,张庚申等.电流变液体阻尼器数学模型研究.液压与气动，2003，（7）：1～3.
[34] Tahir Tilki at.al. Investigation of electrorheological properties ofbiodegradable modified cellulose/corn oil suspensions. CarbohydrateResearch,2010,345:672～679.
[35] Ping Sheng, Weijia Wen. Electrorheology: Statics and dynamics. Solid StateCommunications, 2010, 1016（10）:1～17.
[36]路阳，王学昭等.电流变液研究新进展.材料导报，2009，23（2）：6～10.
[37] X.Z. Wang at.al. The electrode effect on polar molecule dominatedelectrorheological fluids. Materials and Design,2009,（30）：4521～4524.
[38] Young Gun Ko at.al. Influence of particle size on shear behavior ofamine-group-immobilized polyacrylonitrile dispersed suspension under electricfield. Journal of Colloid and Interface Science,2009,335:183～188.
[39]逯静洲,李庆斌.电流变体在结构工程振动控制中的应用研究.烟台大学学报，2010，23（3）：223～228.
[40] Kum-Gil Sung, Young-Min Han at.al. Vibration control of vehicle ERsuspension system using fuzzy moving sliding mode controller. Journal of Soundand Vibration,2008,311:1004～1019.
[41] Seung-Bok Choi,Young-Min Han. Vibration control of electrorheological seatsuspension with human-body model using sliding mode control. Journal of Soundand Vibration,2007,303:391～404.
[42] Seung-Bok Choi,Wan-Kee Kim. Vibration control of a semi-active suspensionfeaturing electrorheological fluid dampers. Journal of Sound andVibration,2000,234(3):537～546.
[43]陈永光，晏华.电流变技术在车辆减振装置中的应用研究.机床与液压,2006,10:103～106.
[44] Michael D. Symans,Michael C. Constantinou. Semi-active control systems forseismic protection of structures: a state-of-the-art review.1999,21:469～487.
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