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石材锯切加工中圆锯片的振动研究
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摘要
论文在剖析石材锯切过程中圆锯片横向振动的研究现状及存在问题的基础上,从理论和实验两个方面展开对圆锯片横向振动的研究,论文的主要研究工作概括如下:
     1、对石材锯切过程中圆锯片横向振动的测量方法进行了研究,为了测量圆锯片的横向绝对振动,采用了三种去除传感器安装基准点振动的方法,并对三种方法进行了实验对比。
     2、对石材锯切过程中圆锯片的横向振动进行了理论建模和实验研究,分析了横向振动信号的时域和频域特性,研究了锯切参数对圆锯片横向振动的影响及横向振动与轴向力的关系,并将解析解与实验结果作了比较分析。
     3、运用ANSYS/LS-DYNA软件对圆锯片锯切花岗石的过程进行了仿真,分析了圆锯片在空转和锯切两种状态下的横向振动特性,并研究了开槽圆锯片的横向振动以及径向槽的个数对圆锯片横向振动的影响。
     通过实验研究和理论分析,本文得到如下结论:
     1、根据石材锯机自身的运动特点,要想测得锯切过程中圆锯片的横向绝对振动,采用非接触测量方法不能解决位移传感器安装点自身的振动问题。在圆锯片上贴电阻应变片,基于无线传感网络实现圆锯片应变信号的实时采集,能实现石材锯切时圆锯片横向绝对振动的可靠测量。
     2、通过锯切花岗石的实验发现,在空转状态下,圆锯片的轴向变形和轴向振动均随着转速的增大而增大;当圆锯片空转转速较高时,横向振动在频域内表现为非线性振动。锯切时圆锯片的横向振动表现为弱非线性特性。
     3、实验表明,圆锯片的轴向变形随切深的增大而增大、随进给速度的增大而增大、随锯片线速度的增大而减小;轴向振动随切深的增大而减小、随锯片线速度的增大而增大,随进给速度的增大而增大。
     4、锯切实验中,在圆锯片完全切入花岗石阶段,横向振动、轴向变形均表现为明显的周期性,周期的长度为圆锯片旋转一周所需的时间,轴向振动的周期性相对较弱。
     5、不同的参数组合下锯切花岗石,圆锯片的轴向变形与所受的轴向力呈近似的线性关系。在锯路形成的过程中,锯片所受的轴向力与轴向变形的变化趋势基本相同。
     6、运用弹性薄板小挠度弯曲的基本理论,将圆锯片简化成一个中间固支、周边自由的圆板,推导出了圆锯片在集中轴向力作用下的横向振动极坐标方程。
     7、将一个周期的轴向变形实验结果与解析模型计算结果进行了对比,实验结果和解析解基本吻合,验证了所建立的解析模型是正确的。
     8、有限元分析发现,锯切花岗石时,圆锯片在锯切弧区附近的区域轴向变形较大,说明此时圆锯片的轴向变形主要受锯缝约束的影响。仿真所得圆锯片一整周的横向振动趋势与解析、实验的轴向变形结果相似。
     9、基体上开径向槽会减小圆锯片的轴向变形,圆锯片轴向变形的最大值随径向槽个数的增多呈减小的趋势,但减小的幅度不大。
Based on the analysis on the research status of transverse vibration of the circularsaw and the existing problem, theoretical and experimental study on transversevibration of the circular saw has been conducted. The main work of this thesis can besummarized as follows:
     1. The measurement method for transverse vibration of circular saw in sawing ofstone has been studied. In order to measure the transverse absolute vibration, threeways to remove vibration from sensor mounting reference point have been proposedand compared with each other according to experimental results.
     2. Theoretical models and experimental studies on transverse vibration of circularsaw in sawing of stone have been conducted. Features of transverse vibration signalshave been analyzed in time and frequency domain respectively. The influence ofsawing parameters on transverse vibration of circular saw and the relationshipbetween transverse vibration and axial force have been studied. Analytical solutionshave been compared with experimental results.
     3. The process of granite sawing by circular saw has been simulated using softwareof ANSYS/LS-DYNA. Transverse vibration characteristics of circular saw in idlingand sawing states have been analyzed. Then, transverse vibration of circular saw withradial slots has been studied. And the number of radial slots effecting on transversevibration has been also discussed.
     Through experimental study and theoretical analysis, the following achievementsand conclusions can be obtained:
     1. In terms of the motion characteristics of stone sawing machine, in order tomeasure the transverse absolute vibration of circular saw in the sawing process, usingnon-contact measurement method can’t solve the vibration problem caused by sensormounting reference point. Another method has been adopted by using strain gagesstuck on the circular saw. Strain signals have been measured online by a developed wireless sensor measuring system, which can realize the reliable measurement oftransverse absolute vibration of circular saw in stone sawing process.
     2. According to the granite sawing experiment, we found that the axial deformationand axial vibration of the circular saw increase with rotating speed in idling state. Infrequency domain, transverse vibration shows as nonlinear vibration at higher idlingrotating speed and weakly nonlinear during the stone sawing process.
     3. The experiments results also show that axial deformation of circular sawincreases with the depth of cut and the feed speed, and decreases with the increasingrotating speed. Axial vibration increases with the feed speed and the rotating speed,and decreases with the increasing depth of cut.
     4. In the experiment, we found that transverse vibration and axial deformationfeatured obvious periodicity. The period is equal to that of circular saw. But theperiodicity of axial vibration is relatively weak.
     5. When sawing granites with different parameters combinations, there is anear-linear relationship between axial deformation of the circular saw and axial forceon it. In kerf forming process, the change tendency of axial deformation and axialforce is similar.
     6. Using the bending theory of small deformation for thin elastic plate,circular sawis simplified to a disk clamped on center and freed on edge. The transverse vibrationpolar equation of circular saw under the concentrated axial force has been deduced.
     7. The results of axial deformation in a period from experiment have beencompared with those from analytical model calculation. The similar results haveverified the correctness of the established analytical model.
     8. Through the FEM analysis, it has been found that in the granite sawing process,larger axial deformation of circular saw happens near the sawing arc zone. The resultsindicate that axial deformation of circular saw is mainly affected by constraint of thesaw kerf. In a cycle of the circular saw, the tendency of transverse vibration given byFEM simulation is similar to that of axial deformation by analysis and experiment.
     9. Axial deformation has been reduced after incision of equally spaced radial slotson the steel core. The maximum axial deformation of the circular saw decreases withincreasing numbers of slot. But the decreasing range is small.
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