基于动态切削过程仿真的外圆车削稳定性判定
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摘要
建立考虑工件轴向和径向两个方向刀具刃倾角和模态方向的车削颤振模型。利用试验得到的切削力系数和模态参数,获得给定机床、刀具和工件组合下的颤振稳定域曲线。建立外圆车削轴类零件的动力学模型,主要包括刀具相对工件的动态切削力和动态位移模型。提出一种借助动态切削力和刀具动态位移时域仿真,以及相邻两转的切削力和位移动态成分映射截面来综合判断切削过程稳定性的方法。通过切削试验验证颤振稳定域判据和动态切削过程判据的准确性。利用该方法了解稳定切削和颤振切削的信号特点和分布规律。对比颤振稳定域和动态切削仿真两种稳定性判据的有效性、优缺点和适用场合,尤其通过典型零件的切削过程仿真说明动态切削仿真方法的优点。此外,还通过对动态切削过程的变模态参数仿真,分析模态参数对切削过程稳定性的影响。
A turning chatter model regarding inclination angle in axial and radial direction of workpiece, and modal direction of machining system is established. Based on the cutting force coefficients and modal parameters obtained from the cutting tests, the chatter stability lobe of given machine tool, tool and workpiece are obtained. The dynamic process models of cylindrical turning shaft are established, including the dynamic displacement between tool and workpiece and dynamic cutting force model. A method with the help of a X-Y mapping section of dynamic cutting force and that of dynamic displacement with the adjacent two spindle revolutions,in combination with time domain simulation signal of dynamic cutting force and dynamic displacement to comprehensively judge cutting process stability is put forward. The accuracy of chatter stability lobe and dynamic cutting process criterion are verified by cutting tests. The effectiveness, advantages and disadvantages of the two stability criteria are compared with the simulation results of the chatter stability lobe and the dynamic cutting simulation. The simulation results show that the dynamic cutting simulation method had the advantage of the simulation of the cutting process. In addition, the influence of the modal parameters on the stability of the cutting process is simulated by the variable parameters simulation of dynamic cutting process.
A turning chatter model regarding inclination angle in axial and radial direction of workpiece, and modal direction of machining system is established. Based on the cutting force coefficients and modal parameters obtained from the cutting tests, the chatter stability lobe of given machine tool, tool and workpiece are obtained. The dynamic process models of cylindrical turning shaft are established, including the dynamic displacement between tool and workpiece and dynamic cutting force model. A method with the help of a X-Y mapping section of dynamic cutting force and that of dynamic displacement with the adjacent two spindle revolutions,in combination with time domain simulation signal of dynamic cutting force and dynamic displacement to comprehensively judge cutting process stability is put forward. The accuracy of chatter stability lobe and dynamic cutting process criterion are verified by cutting tests. The effectiveness, advantages and disadvantages of the two stability criteria are compared with the simulation results of the chatter stability lobe and the dynamic cutting simulation. The simulation results show that the dynamic cutting simulation method had the advantage of the simulation of the cutting process. In addition, the influence of the modal parameters on the stability of the cutting process is simulated by the variable parameters simulation of dynamic cutting process.
引文
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[14]CHIGBOGU G.OZOEGVU,SAM N.O.Time domain chatter stability comparison of turning and milling processes[J].International Journal of Multidisciplinary Sciences and Engineering,2012,3(11):25-30.
[15]ANDREAS O,GUNTER R.Application of spindle speed variation for chatter suppression in turning[J].CIRPJournal of Manufacturing Science and Technology,20136:102-109.
[16]蔡力钢,孙光辉,刘志峰,等.动态激励下多参数对不落轮轮对车削稳定性的影响[J],北京工业大学学报,2016,42(8):1121-1128.CAI Ligang,SUN Guanghui,LIU Zhifeng,et al.Influence of multiparameter with dynamic excitation on turning stability for underfloor wheelsets[J].Journal of Beijing University of Technology,2016,42(8):1121-1128.
[17]KAMBIZ H H,HAMED M,GHOLAMREZA V,et al.Spindle speed variation and adaptive force regulation to suppress regenerative chatter in the turning process[J].Journal of Manufacturing Processes,2010,12,106-115.
[18]谭方浩,焦黎,王西彬,等.基于B样条曲线建模预测复杂型面动态车削力[J],计算机集成制造系统,2014,20(12):3048-3057.TAN Fanghao,JIAO Li,WANG Xibin,et al.Dynamic force prediction model in complex surface turing based on B-spline curves[J].Computer Integrated Manufacturing Systems,2014,20(12):3048-3057.
[19]FENG P F,YU D W,WU Z J.Jaw-chuck stiffness and its influence on dynamic clamping force during high-speed turning[J].International Journal of Machine Tools&Manufacture,2008,48:1268-1275.
[2]石莉,陈尔涛,姜增辉.正交车铣铝合金薄壁回转体振动信号的试验分析[J].兵工学报,2009,30(3):356-360.SHI Li,CHEN Ertao,JIANG Zenghui.Test analysis on vibration signal of thin aluminium-alloy cylinder machined with orthogonal turn-milling[J].Acta Armamentarii,2009,30(3):356-360.
[3]ALWARAAMY T,SANGEETHA N,NAVANEETHANS.Stability and vibration signal analysis in hard turning[C]//The Fifth International Conference on Vibration Engineering and Technology of Machinery.Wuhan:Huazhong University of Science and Technology,2009:27-28.
[4]OZLU E,BUDAK E.Analytical Modeling of chatter stability in turning and boring operations-Part II:Experimental verification[J].Journal of Manufacturing Science and Engineering,2007,129:733-739.
[5]SUH C,KHURJEKAR P,YANG B.Characterisation and identification of dynamic instability in milling operation[J].Mechanical Systems and Signal Processing,2002,16(5):853-872.
[6]BRECHER C,HERMES R,EPPLE A,et al.Simulative parameterization of dead time variable rotation speed behavior to improve process stability in high performance cutting[J].Procedia CIRP,2012,4:2-10.
[7]SCHMITZ T L,SMITH K S.Machining dynamicsfrequency response to improved productivity[M].New York:Springer Science,2009.
[8]ALTINTAS Y.Manufacturing automation:Principles of metal cutting and machine tool vibrations[M].Cambridge:Cambridge University Press,2000.
[9]HAMED M,FIROOZ B N,MOHAMMAD R M.Nonlinear behaviour of the regenerative chatter in turning process with a worn tool:Forced oscillation and stability analysis[J].Mechanism and Machine Theory,2010,45:1050-1066.
[10]ARMAREGO E A,KATTA R K.Predictive cutting model for forces and power in self-propelled roatary tool turning operations[J].Annals of the ClRP,1997,46(1):19-24.
[11]ENDRES W J,SUTHERLAND J W,DEVOR R E.Adynamic model of the cutting force system in the turning process[J].International Journal of Machine Tools and Manufacture,2003,43:1163-1170.
[12]郭瑞琴,武帅,李中.外圆车削加工过程中再生型颤振的建模与分析[J],中国工程机械学报,2015,13(3),252-257.GUO Ruiqin,WU Shuai,LI Zhong.Modeling and analysis on regenerative fluttering for cylindrical turning[J].Chinese Journal of Construction Machinery,2015,13(3):252-257.
[13]李勤良,汪博,赵斌,等.考虑非线性迟滞力的机床颤振系统稳定性研究[J].机械工程学报,2013,49(11):43-49.LI Qinliang,WANG Bo,ZHAO Bin,et al.Research on the chatter stability of machine system taking the nonlinear hysteretic force into consideration[J].Journal of Mechanical Engineering,2013,49(11):43-49.
[14]CHIGBOGU G.OZOEGVU,SAM N.O.Time domain chatter stability comparison of turning and milling processes[J].International Journal of Multidisciplinary Sciences and Engineering,2012,3(11):25-30.
[15]ANDREAS O,GUNTER R.Application of spindle speed variation for chatter suppression in turning[J].CIRPJournal of Manufacturing Science and Technology,20136:102-109.
[16]蔡力钢,孙光辉,刘志峰,等.动态激励下多参数对不落轮轮对车削稳定性的影响[J],北京工业大学学报,2016,42(8):1121-1128.CAI Ligang,SUN Guanghui,LIU Zhifeng,et al.Influence of multiparameter with dynamic excitation on turning stability for underfloor wheelsets[J].Journal of Beijing University of Technology,2016,42(8):1121-1128.
[17]KAMBIZ H H,HAMED M,GHOLAMREZA V,et al.Spindle speed variation and adaptive force regulation to suppress regenerative chatter in the turning process[J].Journal of Manufacturing Processes,2010,12,106-115.
[18]谭方浩,焦黎,王西彬,等.基于B样条曲线建模预测复杂型面动态车削力[J],计算机集成制造系统,2014,20(12):3048-3057.TAN Fanghao,JIAO Li,WANG Xibin,et al.Dynamic force prediction model in complex surface turing based on B-spline curves[J].Computer Integrated Manufacturing Systems,2014,20(12):3048-3057.
[19]FENG P F,YU D W,WU Z J.Jaw-chuck stiffness and its influence on dynamic clamping force during high-speed turning[J].International Journal of Machine Tools&Manufacture,2008,48:1268-1275.