珩磨加工中在线气动测量与尺寸控制技术研究
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摘要
珩磨是磨削加工中一种特殊高效的精加工方法,国产珩磨机无论制造水平、加工精度、还是控制方式等与国外珩磨机相比都存在着较大差距,难以满足高尺寸精度、高形状精度和高度自动化的实际要求,高加工精度、高自动化的数控珩磨机研发及其关键技术的研究成为我国先进制造装备领域的重要研究内容之一。在线测量是数控珩磨机的重要组成部分,是形成珩磨机闭环控制系统的必需环节,也是控制珩磨孔加工尺寸分散度、提高形状精度,保证加工质量的有效手段。
本文以流体力学理论为基础,结合珩磨加工的特点,提出了基于差压式在线气动测量的珩磨加工精度控制的思想,重点研究了测量元件及实际工况对测量精度的影响,在获得高精度测量结果的基础上,通过尺寸预报和在线圆柱度监控分别保证珩磨加工的尺寸精度和形状精度,实现珩磨加工全过程测量。主要研究内容如下：
1.以流体力学理论中的流体运动基本方程为基础,针对珩磨气动测量的特殊应用条件,建立了曲面挡板机构测量模型,提出了当量间隙的概念,建立了差压式气动测量时测量腔的背压在四种工况下的数学模型；确定了当被测工件直径和测量喷嘴外径与测量精度在曲率阈值范围内时,采用本文推导所得方程能够有效提高测量精度；同时,从提高珩磨加工尺寸精度和形状精度的角度,制定了基于气动在线测量的加工尺寸控制策略,明确了将圆柱度作为珩磨加工中形状精度控制的指标。曲面挡板条件下的气动测量数学模型和珩磨加工精度控制策略的建立是本文后续研究的基础。
2.以双进给珩磨头为研究对象,采用理论分析和FLUNT仿真相结合的方法,研究了珩磨头的结构参数和护板参数对测量精度的影响。研究结果表明,主喷嘴的直径影响测量范围,而测量喷嘴直径影响测量系统的分辨率；测量喷嘴外径和长度选择不当会造成测量不稳定,测量喷嘴下沉量与加工余量、测量系统的初始间隙有关；护板倒圆角后能够明显改善测量过程中流场的稳定性。本文提出的珩磨头测量元件结构参数的设计原则,为高精度测量珩磨头优化设计提供了理论依据。
3.利用流体仿真软件FLUENT,对珩磨实际工况下气动测量的精度与珩磨液之间的关系进行了仿真研究,验证了在湿珩状态下,珩磨液在环形窄缝中为层流状态；通过仿真获得了珩磨液在不同温度和粘度条件下的△p-S曲线,确定了当工况温度小于35℃,珩磨液运动粘度在5-8cst(40℃)范围内,可以取得放大倍数和线性范围的最佳值；气动测量的精度与珩磨液参数之间关系的确定为珩磨加工中合理地确定珩磨液,提高测量精度提供了理论依据。
4.从珩前工件宏观形状误差和粗珩加工中引起圆柱度误差的原因入手,研究了珩前工艺、加工余量、珩磨进给速度、冲程、工件装卡方式等因素对工件圆柱度的影响,提出了珩磨加工中控制工件圆柱度误差的整体策略；提出了三截面法和斜率法判定珩前工件宏观形状；提出了在全行程珩磨中结合最小二乘法和二分法、基于投影的圆度最小二乘法两种圆柱度评定模型,并通过仿真验证了两种模型的优缺点和适用范围,确定了结合最小二乘法和二分法模型可以用于珩磨加工在线圆柱度监控。通过珩前宏观形状判定和粗珩中圆柱度监控实现了对珩磨加工中工件形状误差的有效控制。
5.以珩磨加工中加工尺寸序列为研究对象,验证了等维递补预报的预报精度较高,并确定珩磨加工条件下预报模型的最优维数为15维；提出了采用去除畸数据的方法抑制维数对精度的影响,有效解决了灰色预报模型维数不易确定的困难；提出了基于灰色模型和时间序列预报模型的组合预报模型SGM(αt,S0,t,1,1),有效避免了单一模型的局限性,抑制了单一模型的参数对预报精度的过多影响。仿真结果表明在本文所列各种预报模型中,组合预报模型最具有实际使用价值,为珩磨加工尺寸预报模型的建立提供了理论依据。
Honing process is a special grinding efficient finishing method. There is a big gap between domestic honing machine and foreign honing machine both in the level of manufacturing, processing accuracy, and control mode. It is difficult to meet the actual requirements of the high dimensional accuracy, high shape precision and a high degree of automation.High machining accuracy, highly automated CNC honing machine and its key technology has become one of the important research content of the field of advanced manufacturing equipment. On-line measurement is an important part of the CNC honing machine. It is a necessary link to form closed loop control system of the honing machine and the effective means of controlling honing Holes dispersity, improving shape accuracy, and ensuring the quality of processing.
In this paper, based on the elementary theory of fluid dynamics and combining the characteristics of the honing processing, a general idea of the honing machining precision control based on the on-line pneumatic measuring is proposed. This idea focused on the impact of measuring element and the actual conditions on the measurement accuracy in the honing process. On the basic of accurate measurement results, ensure the dimensional accuracy and shape accuracy by size forecast and online cylindricity monitoring to achieve the whole process measurement of honing process.The following are the main content of the research.
(1) According to the basic equations of fluid dymamics theory and the special applications conditions for honing aerodynamic measurements, a curved baffle institutions measurement model is established and the concept of equivalent clearance is put forward, the mathematical model for measurement chamber backpressure in four kinds of difference conditions is established. Meanwhile, for the purpose of rising the honing processing dimensional accuracy and shape accuracy, the strategy of size control in the whole process of honing processing. These are theoretical basis for the honing of on-line measurement system for improving the precision and realize quality control in the whole honing process.
(2) Using Double-feed honing head as the research object, a combination of theoretical analysis and FLUNT simulation as the method to study the structural parameters of the honing head and shield parameter measurement accuracy. The results show that the nozzle diameter and length has relations with the measurement range and precision, and the nozzle settlement should be less than0.035mm, retaining plate fillet can improve the measurement accuracy. These are theoretical basis for the optimization design in design of high precision honing tool.
(3) Study the relationship between the measuring accuracy and the actual conditions of honing liquid based on simulation. First, the flow state of honing liquid in narrow annular gap is laminar flow. And the relationship between the viscosity and temperature of the honing liquid and the magnification and range of the measurement is discussed. The optimum working temperature and viscosity of the honing liquid is determined after the simulation in the different conditions. This is theoretical basis for the reasonable choice for honing liquid.
(4) By systematic analyzing the factors on workpiece cylindricity, the strategy of cylindricity error control for inner honing is proposed for the first time. The three section method and slope method is used for confirming the macroscopic shape error before the honing processing. A new concept of control the shape precision is put forward based on the method of on-line cylindricity monitoring in the course of full area honing. Aiming at the requirement of high accuracy and rapid decision in the cylinder monitoring, two models of cylindricity evaluation are put forward. One is combined with the least square and dichotomy, the other is based on the projection of the least square method for roundness evaluation model. Through the simulation of the two models, the combination of the least square method and dichotomy model can be used for the cylindricity on-line monitoring in the honing process.
(5) Based on the studied of time sequence model and grey model, with the honing machining dimensions for the study object, the essay verified the forecasting has higher accuracy with grey numbers of identical dimensions, and determined the optimal dimension under the condition of honing machining. The method of removal of abnormal data is used to inhibit the effect of dimension on accuracy. It has solved the problem effectively that grey forecasting model dimension is not easy to determine. A novel forecasting model SGM(a1,S0,t,1,1)is proposed, which is the combination based on gray model and time series forecasting model. And the new model can avoided single modle limitations effectively, inhibited the excessive influence of the model parameters of a single model of forecasting accuracy. The essay used honing size deviation to verify the applicability of the various forecasting models, the results show that in the essay lists various forecasting models, and the combination model has the most practical value in forecasting for honing precess.
本文以流体力学理论为基础,结合珩磨加工的特点,提出了基于差压式在线气动测量的珩磨加工精度控制的思想,重点研究了测量元件及实际工况对测量精度的影响,在获得高精度测量结果的基础上,通过尺寸预报和在线圆柱度监控分别保证珩磨加工的尺寸精度和形状精度,实现珩磨加工全过程测量。主要研究内容如下：
1.以流体力学理论中的流体运动基本方程为基础,针对珩磨气动测量的特殊应用条件,建立了曲面挡板机构测量模型,提出了当量间隙的概念,建立了差压式气动测量时测量腔的背压在四种工况下的数学模型；确定了当被测工件直径和测量喷嘴外径与测量精度在曲率阈值范围内时,采用本文推导所得方程能够有效提高测量精度；同时,从提高珩磨加工尺寸精度和形状精度的角度,制定了基于气动在线测量的加工尺寸控制策略,明确了将圆柱度作为珩磨加工中形状精度控制的指标。曲面挡板条件下的气动测量数学模型和珩磨加工精度控制策略的建立是本文后续研究的基础。
2.以双进给珩磨头为研究对象,采用理论分析和FLUNT仿真相结合的方法,研究了珩磨头的结构参数和护板参数对测量精度的影响。研究结果表明,主喷嘴的直径影响测量范围,而测量喷嘴直径影响测量系统的分辨率；测量喷嘴外径和长度选择不当会造成测量不稳定,测量喷嘴下沉量与加工余量、测量系统的初始间隙有关；护板倒圆角后能够明显改善测量过程中流场的稳定性。本文提出的珩磨头测量元件结构参数的设计原则,为高精度测量珩磨头优化设计提供了理论依据。
3.利用流体仿真软件FLUENT,对珩磨实际工况下气动测量的精度与珩磨液之间的关系进行了仿真研究,验证了在湿珩状态下,珩磨液在环形窄缝中为层流状态；通过仿真获得了珩磨液在不同温度和粘度条件下的△p-S曲线,确定了当工况温度小于35℃,珩磨液运动粘度在5-8cst(40℃)范围内,可以取得放大倍数和线性范围的最佳值；气动测量的精度与珩磨液参数之间关系的确定为珩磨加工中合理地确定珩磨液,提高测量精度提供了理论依据。
4.从珩前工件宏观形状误差和粗珩加工中引起圆柱度误差的原因入手,研究了珩前工艺、加工余量、珩磨进给速度、冲程、工件装卡方式等因素对工件圆柱度的影响,提出了珩磨加工中控制工件圆柱度误差的整体策略；提出了三截面法和斜率法判定珩前工件宏观形状；提出了在全行程珩磨中结合最小二乘法和二分法、基于投影的圆度最小二乘法两种圆柱度评定模型,并通过仿真验证了两种模型的优缺点和适用范围,确定了结合最小二乘法和二分法模型可以用于珩磨加工在线圆柱度监控。通过珩前宏观形状判定和粗珩中圆柱度监控实现了对珩磨加工中工件形状误差的有效控制。
5.以珩磨加工中加工尺寸序列为研究对象,验证了等维递补预报的预报精度较高,并确定珩磨加工条件下预报模型的最优维数为15维；提出了采用去除畸数据的方法抑制维数对精度的影响,有效解决了灰色预报模型维数不易确定的困难；提出了基于灰色模型和时间序列预报模型的组合预报模型SGM(αt,S0,t,1,1),有效避免了单一模型的局限性,抑制了单一模型的参数对预报精度的过多影响。仿真结果表明在本文所列各种预报模型中,组合预报模型最具有实际使用价值,为珩磨加工尺寸预报模型的建立提供了理论依据。
Honing process is a special grinding efficient finishing method. There is a big gap between domestic honing machine and foreign honing machine both in the level of manufacturing, processing accuracy, and control mode. It is difficult to meet the actual requirements of the high dimensional accuracy, high shape precision and a high degree of automation.High machining accuracy, highly automated CNC honing machine and its key technology has become one of the important research content of the field of advanced manufacturing equipment. On-line measurement is an important part of the CNC honing machine. It is a necessary link to form closed loop control system of the honing machine and the effective means of controlling honing Holes dispersity, improving shape accuracy, and ensuring the quality of processing.
In this paper, based on the elementary theory of fluid dynamics and combining the characteristics of the honing processing, a general idea of the honing machining precision control based on the on-line pneumatic measuring is proposed. This idea focused on the impact of measuring element and the actual conditions on the measurement accuracy in the honing process. On the basic of accurate measurement results, ensure the dimensional accuracy and shape accuracy by size forecast and online cylindricity monitoring to achieve the whole process measurement of honing process.The following are the main content of the research.
(1) According to the basic equations of fluid dymamics theory and the special applications conditions for honing aerodynamic measurements, a curved baffle institutions measurement model is established and the concept of equivalent clearance is put forward, the mathematical model for measurement chamber backpressure in four kinds of difference conditions is established. Meanwhile, for the purpose of rising the honing processing dimensional accuracy and shape accuracy, the strategy of size control in the whole process of honing processing. These are theoretical basis for the honing of on-line measurement system for improving the precision and realize quality control in the whole honing process.
(2) Using Double-feed honing head as the research object, a combination of theoretical analysis and FLUNT simulation as the method to study the structural parameters of the honing head and shield parameter measurement accuracy. The results show that the nozzle diameter and length has relations with the measurement range and precision, and the nozzle settlement should be less than0.035mm, retaining plate fillet can improve the measurement accuracy. These are theoretical basis for the optimization design in design of high precision honing tool.
(3) Study the relationship between the measuring accuracy and the actual conditions of honing liquid based on simulation. First, the flow state of honing liquid in narrow annular gap is laminar flow. And the relationship between the viscosity and temperature of the honing liquid and the magnification and range of the measurement is discussed. The optimum working temperature and viscosity of the honing liquid is determined after the simulation in the different conditions. This is theoretical basis for the reasonable choice for honing liquid.
(4) By systematic analyzing the factors on workpiece cylindricity, the strategy of cylindricity error control for inner honing is proposed for the first time. The three section method and slope method is used for confirming the macroscopic shape error before the honing processing. A new concept of control the shape precision is put forward based on the method of on-line cylindricity monitoring in the course of full area honing. Aiming at the requirement of high accuracy and rapid decision in the cylinder monitoring, two models of cylindricity evaluation are put forward. One is combined with the least square and dichotomy, the other is based on the projection of the least square method for roundness evaluation model. Through the simulation of the two models, the combination of the least square method and dichotomy model can be used for the cylindricity on-line monitoring in the honing process.
(5) Based on the studied of time sequence model and grey model, with the honing machining dimensions for the study object, the essay verified the forecasting has higher accuracy with grey numbers of identical dimensions, and determined the optimal dimension under the condition of honing machining. The method of removal of abnormal data is used to inhibit the effect of dimension on accuracy. It has solved the problem effectively that grey forecasting model dimension is not easy to determine. A novel forecasting model SGM(a1,S0,t,1,1)is proposed, which is the combination based on gray model and time series forecasting model. And the new model can avoided single modle limitations effectively, inhibited the excessive influence of the model parameters of a single model of forecasting accuracy. The essay used honing size deviation to verify the applicability of the various forecasting models, the results show that in the essay lists various forecasting models, and the combination model has the most practical value in forecasting for honing precess.
引文
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