复杂曲面加工过程中铣刀在线监测方法
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摘要
在验证了铣削力与刀柄摆动电涡流位移信号之间存在线性关系的基础上,以机床主轴端部x,y方向的加速度信号二次频域积分结果作为刀柄摆动位移信号,提取积分位移信号的基频及其谐波信号作为监测信号,解决了电涡流位移传感器安装不便的问题,同时有效去除了干扰信号的影响。利用时域同步平均(time synchronous averaging,简称TSA)计算监测信号的一阶和二阶累积量,结合时域指标方差、偏斜度、峭度、绝对均值及有效值定量刻画累积量波形,通过设定阈值实现状态预警,较好地解决了复杂曲面加工过程中铣刀状态在线监测与预警的难题。
With the development of large precision machinery including aircraft engines,compressors towards high load,high efficiency and high reliability,the quality requirements of the impeller are getting higher and higher.However,as the processing technology for impeller is complex and the cutting condition is unstable,milling tool edge is easily broken in machining process,seriously affecting the quality of impeller.The relationship between the milling force and eddy-current displacement signal of cutter radial swing is verified as a linear tend.The vibration signals of acceleration sampled fromxand ydirections of machine tool spindle end are transferred into vibration signal of displacement with frequency-domain integration algorithm.Then,the fundamental and harmonic components of integration signal are extracted for further analysis,which solves the difficulty of eddy current sensor installation and effectively removes influence of the jamming signal.The first-order cumulant and second-order cumulant with time synchronous averaging algorithm and characterize waveform of the cumulants quantitatively with characteristics are calculated in time domain,which include variance,skew,kurtosis,absolute mean value and RMS.At last,setting threshold can realize the state warning.It can be concluded that the proposed method can solve the problem of online monitoring and early warning of milling cutter condition in complex surface machining process.
With the development of large precision machinery including aircraft engines,compressors towards high load,high efficiency and high reliability,the quality requirements of the impeller are getting higher and higher.However,as the processing technology for impeller is complex and the cutting condition is unstable,milling tool edge is easily broken in machining process,seriously affecting the quality of impeller.The relationship between the milling force and eddy-current displacement signal of cutter radial swing is verified as a linear tend.The vibration signals of acceleration sampled fromxand ydirections of machine tool spindle end are transferred into vibration signal of displacement with frequency-domain integration algorithm.Then,the fundamental and harmonic components of integration signal are extracted for further analysis,which solves the difficulty of eddy current sensor installation and effectively removes influence of the jamming signal.The first-order cumulant and second-order cumulant with time synchronous averaging algorithm and characterize waveform of the cumulants quantitatively with characteristics are calculated in time domain,which include variance,skew,kurtosis,absolute mean value and RMS.At last,setting threshold can realize the state warning.It can be concluded that the proposed method can solve the problem of online monitoring and early warning of milling cutter condition in complex surface machining process.
引文
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[19]孙美玲,朱春吉,岳晓峰,等.时域同步平均在振动信号分析中的应用[J].长春工业大学学报:自然科学版,2014(4):398-401.Sun Meiling,Zhu Chunji,Yue Xiaofeng,et al.Average time domain synchronous method in gearbox fault diagnosis[J].Journal of Changchun University of Technology:Natural Science Edition,2014(4):398-401.(in Chinese)
[2]李精忠.铣削加工稳定性与刀具可靠性研究[D].大连:大连理工大学,2013.
[3]Ertunc H M,Oysu C.Drill wear monitoring using cutting force signals[J].Mechatronics,2004,14(5):533-548.
[4]Ertunc H M,Loparo K A.A decision fusion algorithm for tool wear condition monitoring in drilling[J].International Journal of Machine Tools and Manufacture,2001,41(9):1347-1362.
[5]郑建明,李言,李鹏阳,等.基于切削力信号时域频域特征融合的刀具磨损监测[J].机械与电子,2001(3):46-48.Zheng Jianming,Li Yan,Li Pengyang,et al.Tool wear monitoring based on the fusion of cutting force signals in time domain and frequency domain[J].Mechanical and Electronics,2001(3):46-48.(in Chinese)
[6]陈少波.旋转式动态切削力测量技术的研究[D].上海:同济大学,2003.
[7]Smith D A,Smith S,Tlusty J.High performance milling torque sensor[J].Journal of Manufacturing Science and Engineering,1998,120(3):504-514.
[8]Tansel I N,Demetgul M,Bickraj K,et al.Basic computational tools and mechanical hardware for torquebased diagnostic of machining operations[J].Journal of Intelligent Manufacturing,2013,24:147-161.
[9]欧阳惠斌.基于功率变化率的刀具破损监测系统[J].仪表技术,2003(2):20-21.Ouyang Huibin.The cutting tools breakage monitor system based on power change rate[J].Instrument Technique,2003(2):20-21.(in Chinese)
[10]Romero T R,Gilberto H R.Driver current analysis for sensorless tool breakage monitoring of CNC milling machines[J].International Journal of Machine Tools&Manufacture,2003,43(15):1529-1534.
[11]Bassiuny A M,Li X.Flute breakage detection during end milling using Hilbert-Huang transform and smoothed nonlinear energy operator[J].International Journal of Machine Tools and Manufacture,2007,47(6):1011-1020.
[12]王细洋,龙亮,郭敏.基于振动信号的刀具状态监控技术研究[J].南昌航空大学学报:自然科学版,2011(3):42-47.Wang Xilong,Long Liang,Guo Min.Study on cutting tool state monitoring technology based on the wavelet analysis of vibration signals[J].Journal of Nanchang Hangkong University:Natural Sciences,2011(3):42-47.(in Chinese)
[13]陈群涛,石新华,邵华.基于振动信号EMD和ICA的刀具破损识别[J].工具技术,2012,12:53-58.Chen Quntao,Shi Xinhua,Shao Hua.Vibration signal processing for tool breakage monitoring based on EMD and ICA[J].Tool Engineering,2012,12:53-58.(in Chinese)
[14]Roth J T,Pandit S M.Monitoring end-mill wear and predicting tool failure using accelerometers[J].Journal of Manufacturing Science and Engineering,1999,121(4):559-567.
[15]朱坚民,王健,张统超,等.基于刀具振动位移的动态铣削力测量方法[J].仪器仪表学报,2014,12:2772-2782.Zhu Jianmin,Wang Jian,Zhang Tongchao,et al.Dynamic milling force measuring method based on cutting tool vibration displacement[J].Chinese Journal of Scientific Instrument,2014,12:2772-2782.(in Chinese)
[16]Sarhan A A D,Matsubara A.Investigation about the characterization of machine tool spindle stiffness for intelligent CNC end milling[J].Robotics and ComputerIntegrated Manufacturing,2015(34):133-139.
[17]徐庆华.试采用FFT方法实现加速度、速度与位移的相互转换[J].振动、测试与诊断,1997(2):30-34.Xu Qinghua.Conversion between vibrational acceleration velocity and displacement using FFT[J].Journal of Vibration,Measurement&Diagnosis,1997(2):30-34.(in Chinese)
[18]顾名坤,吕振华.基于振动加速度测量的振动速度和位移信号识别方法探讨[J].机械科学与技术,2011(4):522-526.Gu Mingkun,LüZhenhua.Identification of a mechanism's vibration velocity and displacement based on the acceleration measurement[J].Mechanical Science and Technology for Aerospace Engineering,2011(4):522-526.(in Chinese)
[19]孙美玲,朱春吉,岳晓峰,等.时域同步平均在振动信号分析中的应用[J].长春工业大学学报:自然科学版,2014(4):398-401.Sun Meiling,Zhu Chunji,Yue Xiaofeng,et al.Average time domain synchronous method in gearbox fault diagnosis[J].Journal of Changchun University of Technology:Natural Science Edition,2014(4):398-401.(in Chinese)