微小铣床动态特性分析与优化研究
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摘要
为满足对三维微小零件的需求,本实验室研制开发了一台微小铣床,并对其进行了静、动态特性分析。
首先,对微小铣床的关键部件--电主轴和龙门架进行了静态特性、动态特性研究,分析时考虑了结合部的影响。在此基础上,对微小铣床和关键部件进行优化研究,为提出新的铣床结构奠定了基础。
龙门架与底座之间为螺栓连接,通过理论计算,得出了螺栓结合部的参数。为考察螺栓结合部的柔性对整个床身结构动态特性的影响,计算了刚度系数在一定范围内变化时结构的频率和振型。
对电主轴进行静态特性分析,求出电主轴的静刚度,同时进行了模态分析、谐响应分析及瞬态分析,分别得出电主轴的固有频率及振型、共振频率及最大动态位移、瞬态冲击下主轴的变形。
在全面静动态分析的基础上,对床身结构与主轴进行了优化研究。对于电主轴,采用形状优化和广义概念上的优化,得出电主轴的最佳尺寸。对于龙门架,采用拓扑优化,得到最大刚度化的龙门架的形状。
在改进的电主轴和龙门架的结构的基础上,提出新的微小铣床的设计方案,与已开发的小铣床相比,不仅体积和重量都有相当程度的缩小,而动态性能也有所提高。本文的研究为下一步微小机床的改进与开发奠定了基础。
Due to miniaturization, the machine tools are required to have high rigidity and good dynamic properties to ensure the process accuracy. Therefore, dynamic analyses are necessary.
In this paper, for a small milling machine developed by our lab, the static and dynamic analyses are performed and the optimizations of the key components of the machine are carried out.
The static and dynamic characteristics of the Gantry and spindle are analyzed firstly considering the effects of the flexible joints. The interface parameters are obtained through theoretical methods. The dynamic behaviors of the key components are investigated by changing the stiffness of the bolt joints.
Based on the analyses, the machine system is optimized by topological Improvement using ANSYS. Also, a new design scheme is proposed. The sizes of the new meso scale milling machine are reduced and the rigidity is enhanced. This study can provide foundations for developing the next generation of the miniaturized machine tool.
首先,对微小铣床的关键部件--电主轴和龙门架进行了静态特性、动态特性研究,分析时考虑了结合部的影响。在此基础上,对微小铣床和关键部件进行优化研究,为提出新的铣床结构奠定了基础。
龙门架与底座之间为螺栓连接,通过理论计算,得出了螺栓结合部的参数。为考察螺栓结合部的柔性对整个床身结构动态特性的影响,计算了刚度系数在一定范围内变化时结构的频率和振型。
对电主轴进行静态特性分析,求出电主轴的静刚度,同时进行了模态分析、谐响应分析及瞬态分析,分别得出电主轴的固有频率及振型、共振频率及最大动态位移、瞬态冲击下主轴的变形。
在全面静动态分析的基础上,对床身结构与主轴进行了优化研究。对于电主轴,采用形状优化和广义概念上的优化,得出电主轴的最佳尺寸。对于龙门架,采用拓扑优化,得到最大刚度化的龙门架的形状。
在改进的电主轴和龙门架的结构的基础上,提出新的微小铣床的设计方案,与已开发的小铣床相比,不仅体积和重量都有相当程度的缩小,而动态性能也有所提高。本文的研究为下一步微小机床的改进与开发奠定了基础。
Due to miniaturization, the machine tools are required to have high rigidity and good dynamic properties to ensure the process accuracy. Therefore, dynamic analyses are necessary.
In this paper, for a small milling machine developed by our lab, the static and dynamic analyses are performed and the optimizations of the key components of the machine are carried out.
The static and dynamic characteristics of the Gantry and spindle are analyzed firstly considering the effects of the flexible joints. The interface parameters are obtained through theoretical methods. The dynamic behaviors of the key components are investigated by changing the stiffness of the bolt joints.
Based on the analyses, the machine system is optimized by topological Improvement using ANSYS. Also, a new design scheme is proposed. The sizes of the new meso scale milling machine are reduced and the rigidity is enhanced. This study can provide foundations for developing the next generation of the miniaturized machine tool.
引文
[1]T.Kurita,M.Hattori.Development of new-concept desk top size machine tool[J].International Journal of Machine Tools & Manufacture Design Research and Application,2005,(45):959-965.
[2]LIU Teijun,Huang Zhiyao,Wang Baoliang,et al.High Speed Electrical Resistance Tomography System Based on Bi2directional Pulse Current Technique.The 4th International Symposiumon Measurment Techniques of Multiphase Flows,Hangzhou,2004:194-198.
[3]孙雅洲,梁迎春,程凯 微型化制造设备与微型制造系统[J],中国机械工程,2002,13(7):592-5961.
[4]Yuichi Okazaki,Nozomu Mishima and Kiwamu Ashida.Microfactory-Concept,History and Developments[J].Journal of Manufacturing Science and Engineering,2004,(126):837-844.
[5]Nozomu MISHIMA.Robust Conceptual Design of Machine Tools[C].Selected Articles of the 1~(st) International Conference on Design Engineering and Science,2005.
[6]J.Chae,S.S.Park,T.Freiheit.Investigation of micro-cutting operations[J].International Journal of Machine Tools &Manufacture 46(2006) 313-332.
[7]Ehmann KF,Bourell D1WTEC Panel Report on International Assessment of Research and Development in Micro-manufacturing[R].USA:WTEC,2005.
[8]Yuichi Okazaki,Nozomu Mishima and Kiwamu Ashida.Microfactory-Concept,History and Developments[J].Journal of Manufacturing Science and Engineering,2004,(126):837-844.
[9]Ashida,K.,Mishima,N.,Maekawa,H.,Tanikawa,T.,Kaneko,K.,and Tanaka,M.,Development of desktop machining Microfactory,Proc.J-USA Symposium on Flexible Automation,2000,pp.175-178.
[10]Okazaki,Y.,and Kitahara,T.,NC microlathe to machine micro-parts,Proc.2000 ASPE Annual Meeting,2000,pp.575-578.
[11]#12
[12]Andrew E.Honegger,etc.Development of an automated microfactory:part1-microfactory architecture and sub-systems development.
[13]World Technology Evaluation Center.International Assessment of Research and Development in Micromanufacturing.http://www.wtec.org/micromfg.2006.
[14]Kornel F.,Ehmann.A synopsis of U.S.micro-manufacturing research and development activities and trends[C].4M 2007 Conference Borovets,Bulgaria,October 2007.
[15]赵岩,梁迎春.微细加工中的微型铣床、微刀具磨损及切削力的实验研究[J].光学精密工程,2007,15(6):894-900.
[16]孙雅洲,高强,梁迎春.超声电机在微小型机床进给系统中的应用[J].组合机床与自动化加工技术,2006,(4):11-14.
[17]张之敬,金鑫,周敏.精密微小型制造理论、技术及其应用[J].机械工程学报,2007,43(1):49-61.
[18]张霖,赵东标.微细切削用小型数控铣床的研制[J].东南大学学报(自然科学版),2007,(37):27-29.
[19]Xinmin Lai,Hongtao Li,Chengfeng Li,Jun Ni,Lin Zhongqin.Modeling and Analysis of Meso Scale Milling Process Considering Size Effect,Micro Cutter Edge Radius and Minimum Chip Thickness,International Journal of Machine Tools and Manufacture,2008,48(1):1-14.
[20]孙雅洲,梁迎春,程凯。微型化制造设备与微型制造系统[J]。中国机械工程,2002,Vol.13(7):592-596
[21]Mekid S.,Gordon A.and Nicholson P.Challenges and Rationale in the Design of Miniaturised Machine Tool.International MATADOR Conference.Manchester.465-471.
[22]Mishima N.,Ashida K.,Tanikawa T.and Maekawa H.Design of a Microfactory.Institute of Mechanical Systems Engineering,National Institute of Advanced Industrial Science and Technology,Tsukuba,Ibaraki,305-8564,JAPAN.
[23]Weck,M.,Miessen,W.,Finke,R.,and Mueller,W.,1975,"Application of the Finite Element Method for the Analysis of the Dynamic Behavior of Damped Machine Tools," CIRP Ann.,24_1_,pp.303-307.
[24]Inamura,T.,1983,"Dynamic Analysis of a Machine-Tool Structure and Its Problems," Bull.Jpn.Soc.Precis.Eng.,17_4_,pp.225-230.
[25]Sata,T.,Yasui,T.,Okubo,N.,Suzuki,H.,Naritomi,T.,and Yamada,T.,1976,"Development of Machine Tool Structure Analysis Program_MASAP_," CIRP Ann.,25_1_,pp.287-290.
[26]Shin,Y.C.,Eman,K.F.,and Wu,S.M.,1989,"Experimental Complex Modal Analysis of Machine Tool Structures," ASME J.Eng.Ind.,111,pp.116-124.
[27]Eman,K.F.,and Kim,K.J.,1983,"Modal Analysis of Machine Tool Structures Based on Experimental Data,"ASME J.Eng.Ind.,105,pp.282-287.
[28]Jenkins,H.E.,and Kurfess,T.R.,1997,"Dynamic Stiffness Implications for a Multiaxis Grinding System," J.Vib.Control,3,pp.297-313.
[29]S W Lee,R Mayor and Jun Ni.Dynamic Analysis of a Mesoscale Machine Tool.Transactions of the ASME,Vol.128,2006,194-203.
[30]Burdekin,M.,Back,N.,and Cowley,A.,1978,"Experimental Study of Normal and Shear Characteristics of Machined Surfaces in Contact," J.Mech.Eng.Sci.,20(3),pp.129-132.
[31]Crawley,E.F.,and Aubert,A.C.,1986,"Identification of Nonlinear Structural Elements By Force-State Mapping",AIAA J.,24(1),pp.155-162.
[32]Ren,Y.,and Beards,C.F.,1998,"Identification of 'Effective' Linear Joints Using Coupling and Joint Identification Techniques," Trans.ASME,J.Vib.Acoust.,120,pp.331-338.
[33]Ren,Y.,and Beards,C.F.,1995,"Identification of Joint Properties of a Structure Using FRF Data," J.Sound Vib.,186(4),pp.567-587.
[34]Schmitz,T.L.,Davies,M.A.,and Kennedy,M.D.,2001,"Tool Point Frequency Response Prediction for High-Speed Machining by RCSA," ASME J.Manuf.Sci.Eng.,123,pp.700-707.
[35]Yigit,A.S.,and Ulsoy,A.G.,2002,"Dynamic Stiffness Evaluation for Reconfigurable Machine Tools Including Weakly Non-linear Joint Characteristics," Proc.Inst.Mech.Eng.,Part B,216(1),pp.87-101.
[36]Kim,S.,Ha,J.,Jeong,S.,and Lee,S.,2001,"Effect of Joint Conditions on the Dynamic Behavior of a Grinding Wheel Spindle," Int.J.Mach.Tools Manuf.,41,pp.1749-1761.
[37]Y.Altintas,M.Weck,Chatter stability of metal cutting and grinding,Annals of CIRP 53/2(2004) 619--642.
[38]Yuzhong Cao,Y.Altintas,Modeling of spindle-bearing and machine tool systems for virtual simulation of milling operations.International Journal of Machine Tools & Manufacture 47(2007) 1342-1350。
[39]Robinson GM and Jackson M F.A review of micro and nano machining from a materials perspective.Journal of Materials Processing Technology;y,2005..
[40]殷增振.主轴系统实验台理论建模及结合部动态特性研究.2005.
[41]Ynzhong Cao,Y.Altintas.Modeling of spondle-bearing and machine tool systems for virtual simulation of milling operations.2006.
[42]罗建平,刘泓滨,王立华,郭晟.数控铣床主轴结合部参数识别及动态特性分析.机械电子.2007.
[43]秋峰,桌面式微小铣床结构设计与仿真分析.长春理工大学硕士学位论文.2009.
[44]廖伯瑜,周新民,尹志宏.现代机械动力学及其工程应用[M].机械工业出版社.1-5.
[45]吴善元.金属切削原理与刀具[M].机械工业出版社,1995.
[46]李兵,何正嘉,陈雪峰.ANSYS Workbench设计仿真与优化[M].清华大学出版社.2008.
[47]胡爱玲.高速电主轴动静态特性的有限元分析.广东工业大学硕士论文.2004.
[48]梁双翼,尹辉俊,陈晨,宋世柳.高速电主轴的有限元分析,2007.
[49]张朝晖.ANSYS8.0结构分析及实例解析[M].北京:机械工业出版社,2005.
[50]张波,虎恩典,陈天宁等.数控机床主轴部件动态优化设计.机械设计.2004.
[2]LIU Teijun,Huang Zhiyao,Wang Baoliang,et al.High Speed Electrical Resistance Tomography System Based on Bi2directional Pulse Current Technique.The 4th International Symposiumon Measurment Techniques of Multiphase Flows,Hangzhou,2004:194-198.
[3]孙雅洲,梁迎春,程凯 微型化制造设备与微型制造系统[J],中国机械工程,2002,13(7):592-5961.
[4]Yuichi Okazaki,Nozomu Mishima and Kiwamu Ashida.Microfactory-Concept,History and Developments[J].Journal of Manufacturing Science and Engineering,2004,(126):837-844.
[5]Nozomu MISHIMA.Robust Conceptual Design of Machine Tools[C].Selected Articles of the 1~(st) International Conference on Design Engineering and Science,2005.
[6]J.Chae,S.S.Park,T.Freiheit.Investigation of micro-cutting operations[J].International Journal of Machine Tools &Manufacture 46(2006) 313-332.
[7]Ehmann KF,Bourell D1WTEC Panel Report on International Assessment of Research and Development in Micro-manufacturing[R].USA:WTEC,2005.
[8]Yuichi Okazaki,Nozomu Mishima and Kiwamu Ashida.Microfactory-Concept,History and Developments[J].Journal of Manufacturing Science and Engineering,2004,(126):837-844.
[9]Ashida,K.,Mishima,N.,Maekawa,H.,Tanikawa,T.,Kaneko,K.,and Tanaka,M.,Development of desktop machining Microfactory,Proc.J-USA Symposium on Flexible Automation,2000,pp.175-178.
[10]Okazaki,Y.,and Kitahara,T.,NC microlathe to machine micro-parts,Proc.2000 ASPE Annual Meeting,2000,pp.575-578.
[11]#12
[12]Andrew E.Honegger,etc.Development of an automated microfactory:part1-microfactory architecture and sub-systems development.
[13]World Technology Evaluation Center.International Assessment of Research and Development in Micromanufacturing.http://www.wtec.org/micromfg.2006.
[14]Kornel F.,Ehmann.A synopsis of U.S.micro-manufacturing research and development activities and trends[C].4M 2007 Conference Borovets,Bulgaria,October 2007.
[15]赵岩,梁迎春.微细加工中的微型铣床、微刀具磨损及切削力的实验研究[J].光学精密工程,2007,15(6):894-900.
[16]孙雅洲,高强,梁迎春.超声电机在微小型机床进给系统中的应用[J].组合机床与自动化加工技术,2006,(4):11-14.
[17]张之敬,金鑫,周敏.精密微小型制造理论、技术及其应用[J].机械工程学报,2007,43(1):49-61.
[18]张霖,赵东标.微细切削用小型数控铣床的研制[J].东南大学学报(自然科学版),2007,(37):27-29.
[19]Xinmin Lai,Hongtao Li,Chengfeng Li,Jun Ni,Lin Zhongqin.Modeling and Analysis of Meso Scale Milling Process Considering Size Effect,Micro Cutter Edge Radius and Minimum Chip Thickness,International Journal of Machine Tools and Manufacture,2008,48(1):1-14.
[20]孙雅洲,梁迎春,程凯。微型化制造设备与微型制造系统[J]。中国机械工程,2002,Vol.13(7):592-596
[21]Mekid S.,Gordon A.and Nicholson P.Challenges and Rationale in the Design of Miniaturised Machine Tool.International MATADOR Conference.Manchester.465-471.
[22]Mishima N.,Ashida K.,Tanikawa T.and Maekawa H.Design of a Microfactory.Institute of Mechanical Systems Engineering,National Institute of Advanced Industrial Science and Technology,Tsukuba,Ibaraki,305-8564,JAPAN.
[23]Weck,M.,Miessen,W.,Finke,R.,and Mueller,W.,1975,"Application of the Finite Element Method for the Analysis of the Dynamic Behavior of Damped Machine Tools," CIRP Ann.,24_1_,pp.303-307.
[24]Inamura,T.,1983,"Dynamic Analysis of a Machine-Tool Structure and Its Problems," Bull.Jpn.Soc.Precis.Eng.,17_4_,pp.225-230.
[25]Sata,T.,Yasui,T.,Okubo,N.,Suzuki,H.,Naritomi,T.,and Yamada,T.,1976,"Development of Machine Tool Structure Analysis Program_MASAP_," CIRP Ann.,25_1_,pp.287-290.
[26]Shin,Y.C.,Eman,K.F.,and Wu,S.M.,1989,"Experimental Complex Modal Analysis of Machine Tool Structures," ASME J.Eng.Ind.,111,pp.116-124.
[27]Eman,K.F.,and Kim,K.J.,1983,"Modal Analysis of Machine Tool Structures Based on Experimental Data,"ASME J.Eng.Ind.,105,pp.282-287.
[28]Jenkins,H.E.,and Kurfess,T.R.,1997,"Dynamic Stiffness Implications for a Multiaxis Grinding System," J.Vib.Control,3,pp.297-313.
[29]S W Lee,R Mayor and Jun Ni.Dynamic Analysis of a Mesoscale Machine Tool.Transactions of the ASME,Vol.128,2006,194-203.
[30]Burdekin,M.,Back,N.,and Cowley,A.,1978,"Experimental Study of Normal and Shear Characteristics of Machined Surfaces in Contact," J.Mech.Eng.Sci.,20(3),pp.129-132.
[31]Crawley,E.F.,and Aubert,A.C.,1986,"Identification of Nonlinear Structural Elements By Force-State Mapping",AIAA J.,24(1),pp.155-162.
[32]Ren,Y.,and Beards,C.F.,1998,"Identification of 'Effective' Linear Joints Using Coupling and Joint Identification Techniques," Trans.ASME,J.Vib.Acoust.,120,pp.331-338.
[33]Ren,Y.,and Beards,C.F.,1995,"Identification of Joint Properties of a Structure Using FRF Data," J.Sound Vib.,186(4),pp.567-587.
[34]Schmitz,T.L.,Davies,M.A.,and Kennedy,M.D.,2001,"Tool Point Frequency Response Prediction for High-Speed Machining by RCSA," ASME J.Manuf.Sci.Eng.,123,pp.700-707.
[35]Yigit,A.S.,and Ulsoy,A.G.,2002,"Dynamic Stiffness Evaluation for Reconfigurable Machine Tools Including Weakly Non-linear Joint Characteristics," Proc.Inst.Mech.Eng.,Part B,216(1),pp.87-101.
[36]Kim,S.,Ha,J.,Jeong,S.,and Lee,S.,2001,"Effect of Joint Conditions on the Dynamic Behavior of a Grinding Wheel Spindle," Int.J.Mach.Tools Manuf.,41,pp.1749-1761.
[37]Y.Altintas,M.Weck,Chatter stability of metal cutting and grinding,Annals of CIRP 53/2(2004) 619--642.
[38]Yuzhong Cao,Y.Altintas,Modeling of spindle-bearing and machine tool systems for virtual simulation of milling operations.International Journal of Machine Tools & Manufacture 47(2007) 1342-1350。
[39]Robinson GM and Jackson M F.A review of micro and nano machining from a materials perspective.Journal of Materials Processing Technology;y,2005..
[40]殷增振.主轴系统实验台理论建模及结合部动态特性研究.2005.
[41]Ynzhong Cao,Y.Altintas.Modeling of spondle-bearing and machine tool systems for virtual simulation of milling operations.2006.
[42]罗建平,刘泓滨,王立华,郭晟.数控铣床主轴结合部参数识别及动态特性分析.机械电子.2007.
[43]秋峰,桌面式微小铣床结构设计与仿真分析.长春理工大学硕士学位论文.2009.
[44]廖伯瑜,周新民,尹志宏.现代机械动力学及其工程应用[M].机械工业出版社.1-5.
[45]吴善元.金属切削原理与刀具[M].机械工业出版社,1995.
[46]李兵,何正嘉,陈雪峰.ANSYS Workbench设计仿真与优化[M].清华大学出版社.2008.
[47]胡爱玲.高速电主轴动静态特性的有限元分析.广东工业大学硕士论文.2004.
[48]梁双翼,尹辉俊,陈晨,宋世柳.高速电主轴的有限元分析,2007.
[49]张朝晖.ANSYS8.0结构分析及实例解析[M].北京:机械工业出版社,2005.
[50]张波,虎恩典,陈天宁等.数控机床主轴部件动态优化设计.机械设计.2004.