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磨削工艺系统的动态特性及应用研究
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摘要
磨床的稳定磨削是保证磨削加工顺利进行和获得高加工质量的前提条件和关键技术之一。磨削工艺系统是磨床、刀具、夹具和工件的统一体,其动态性能的优劣对稳定磨削起到了至关重要的作用。本文基于非线性理论,通过对磨削加工过程的分析,研究了非线性振动与各种因素之间的关系,提出抑制磨削振动的措施;将有限元法和实验模态分析法结合,分析了磨床的砂轮架主轴与砂轮轴连接状态时自由模态和工况模态下的动态特性;基于不平衡量系统分析了砂轮轴的振动特性;对砂轮轴系统进行了动平衡分析,设计了动平衡补偿装置;基于动态子结构法,采用理论分析、试验测试和数值计算相结合的方法,系统地分析了高精密磨床的动态特性,并对薄弱的部件提出了改进方案。
     主要的研究工作包括以下几个方面:
     (1)针对外圆磨削加工领域的非线性理论进行了研究,建立了磨削过程中非线性振动模型,研究了砂轮与工件界面间的角频率、非线性阻尼和非线性刚度等参数对系统振动的影响,提出了保证磨削加工质量增加阻尼和增大刚度的方法。基于多尺度法,对磨削加工过程的共振区、非振区等的非线性振动性进行了定量分析,得到主共振和非主共振下的幅频率特性方程,有效地揭示了磨削过程的非线性规律,为磨削过程中提高加工质量的途径提供了理论依据。
     (2)基于弹性理论,采用有限元分析和实验模态分析相结合的方法,构建了主轴/砂轮轴系统在自由状态、工况约束条件下的动力学模型,计算出系统的各阶固有频率和振型,通过实验模态分析方法验证了有限元模型的合理性,进一步分析了该磨床主轴转速对刀柄与主轴接触应力的影响,轴向拉紧力对主轴/刀柄连接刚度、固有频率和阻尼比的影响及工具系统结构的薄弱位置等。
     (3)建立了不平衡量砂轮轴系统的有限元模型,并在此模型基础上研究了砂轮轴系统的不平衡质量引起的砂轮、刀柄端面和刀柄锥面等各个部分的振动情况;研究了转速对砂轮轴系统振动量的影响;研究了砂轮系统的不平衡量值对工件质量的影响。
     (4)从控制工程和计算力学的角度出发,设计了砂轮轴系统动平衡补偿装置。将动平衡校正前后砂轮轴系统的动平衡精度等级、振动值及加工工件表面粗糙度值进行了比较,得出了在不同的转速下,经过动平衡装置补偿后,砂轮轴系统振幅值大幅减小,砂轮轴的平衡精度等级高于补偿前;基于影响系数法对采用所设计的动平衡补偿装置的砂轮轴系统进行了单面和双面动快速动平衡,使得动平衡过程中配重补偿次数少于动平衡补偿前的次数,缩短了平衡时间,提高了生产效率,证明了设计的动平衡补偿装置对提高加工工件的表面粗糙度值及提高加工效率是有效、可行的。
     (5)建立了高效精密磨床各子结构结合部等效动力学模型。通过频响函数试验识别了某高效精密磨床各子结构结合面间刚度、阻尼动力学参数值,并对各子结构之间连接方式为固定锥度接合部、滚动轴承结合部、滑动导轨结合部和螺栓结合部的各子结构进行数值计算,得出低阶固有频率和振型,并进一步通过试验测试结果修正模型边界条件,获得的结构动态特性数值计算结果与真实工况接近,为结构动态优化提供了依据。
     (6)基于动态子结构法,将高效精密磨床结构及其连接方式按各部件功能及其不同的组合方式,划分为砂轮—主轴系统、头架—工件主轴系统、砂轮架、立柱、工作台、床身、砂轮架拖板和工作台拖板等子结构;通过试验模态方法识别的各子结构结合部间的刚度、阻尼等参数值,应用ANSYS有限元分析软件对精密磨床各子结构进行了动态特性分析;对整机进行了动态特性分析,进一步证明了各子结构仿真结果的准确性;对其结构设计的不足之处提出了改进方案。
The stab le grind ing is one of the precond itio n and the key techno logies ofsmoothly mac hining and getting high qua lity on grind ing mac hine. Grind ingprocess syste m is the unity o f grind ing mac hine, tool, c la mp a nd workp iece. Itsdyna mic property is fata l to steady grind ing. In this paper, based on the no nlineartheory, the no nlinear vibratio n on re latio ns hip a mong the vario us factors isstud ied.And so me meas ures are p ut forward to restra in the grind ing vibrationthro ugh the ana lys is o f the grind ing process. Dyna mic characteristics are stud ied ongrind ing wheel sp ind le a nd grind ing whee l in both free mode and working mode,thro ugh connecting the finite e le me nt method and experime nta l modal a na lys is.Based on unba la nce syste m, the vibratio n characteristic o f the spind le isana lyzed.A co mpensatio n device is des igned for the d yna mic ba la nc ing o f grind ingwhee l.Dyna mic characteristics of grind ing process syste m are ana lyzed sys te matic,based on dyna mic substructure technique. Thro ugh the theoretical a na lys is,experimenta l test a nd nume rica l co mputa tion method, so me impro ving projects areput forward.
     Main research’s work inc ludes the fo llowing aspects:
     (1) Nonlinear theory is stud ied on externa l cylindrica l grind ing, and thenonlinear vibratio n model o f grind ing process are establis hes. The influe nce ofparameters o f the angular freque nc y, the no nlinear damp ing a nd no nlinear stiffnessof interface between grind ing whee l a nd workpiece are stud ied, to put forwardmothods on the grind ing q ua lity o f increas ing damp ing and stiffness. Based onmulti-sca le method, quantitative ana lys is is researched on the ma in resonance, andthe nonlinear resona nce regio n o f grind ing process.It get c haracteristic equatio n onamp litude freque ncy o f the primary resona nce and no n-resona nce. It effective lyrevea ls the rule o f the nonlinearity of the grind ing process, to provide a theoreticalbasis for impro ving the processing qua lity.
     (2) Based on the e lastic theory, us ing finite ele me nt a na lys is and e xperime nta lmoda l ana lys is method, the dyna mica l mode ls are constructed on thespind le/sp ind le s yste m in free state, and the working condition. The natura lfreq uenc y and vibra tion mode of the syste m are ca lcula ted. Ratio na lity o f the finiteele me nt mode l is vethrified b y experime nta l moda l a na lys is method, and furtherana lyzes the influence o f the grinder spind le speed to contact stress, axia l te ns ionforce, connectio n stiffness, natura l freque nc y and damp ing ratio o f the syste m structure, and weak pos itio n of structure tools, etc.
     (3)The finite e le me nt model o f unba la nce spind le sys te m is established.Andthe vibratio n of each part on grind ing whee l spind le, the ha ndle end face and ha nd lecone are stud ied. The influe nce of vibratio n ma gnitude of the rotationa l speed inspind le syste m and the unba la nce va lue o f grind ing whee l syste m to the qua lity ofthe workpiece are stud ied.
     (4) From the perspective o f contro l e ngineering a nd comp utationa l mec ha nics,the device o f adjus tive co mpensatio n of dyna mic ba lanc ing is designed on thespind le syste m. The precis io n grade of the dyna mic bala nc ing, vibratio n va lue andthe processing workp iece surface roughness are co mpared before and after dyna miccorrection sys te m, and get a co nc lus io n about the va lue of vibratory a mp litude isdecreased significa ntly a fter d yna mic bala nce.The ba lance o f sp ind le accuracygrade is higher tha n be fore the co mpensatio n. Based on the method of influe ncecoeffic ie nt, methods of fast dyna mic ba lanc ing of the s ingle a nd doub le side areapp lied on the grind ing whee l s yste m. Not only it s hortens the eq uilibrium times,but also imp roves the product ing effic ienc y. It proves that the design ofcompensatio n device of dyna mic bala nc ing for impro ving the va lue of workpiecesurface is e ffective and feasib le.
     (5)Equiva le nt dyna mics model o f each substructure is set up on an effic ientinte gratio n of a prec is ion grind ing machine. By tests of freq uenc y responsefunction, va lues of stiffness and damp ing parameter are ide ntified. Numerica lcalc ulation is done to each substructure for joints of fixed taper, the rolling bearing,slid ing ra il, and bo lt, etc.There force, natura l freq uenc y and vibratio n model areobtained.
     (6) Based on the method of d yna mic s ubstructure, a high precis io n grind ingmac hine structure is d ivided into d ifferent s ubstructures of grind ing whee l---spind le syste m, headstock---the workp iece spindle s yste m, grind ing whee l fra me,column, operating p latform, bed, dragging p late o f grind ing whee l a nd draggingplate o f operating p latform. The parameters s uc h as stiffness, da mp ing va luesbetween each substructure are ide ntified through experime nta l modal method.Dyna mic c haracteristics o f prec is ion grind ing machine o f each s ubstructure areana lyzed in the software of finite e le ment ana lys is. Thro ugh ana lys is o f dyna miccharacteristics o n who le the mac hine, the acc uracy o f the s imulatio n and res ults ofthe substructure are further proved.
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