三向压电式车削测力仪的性能研究与结构设计
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摘要
随着切削加工向高速、高精度、高度自动化方向发展，对切削过程的监控技术也提出了越来越高的要求，而各种自动化机械加工设备与制造系统绝大多数并不具备加工过程的监控功能。为了使这些高度自动化加工设备充分发挥其优良性能，确保加工质量，提高生产效率，对刀具加工过程进行状态监测与控制就越来越重要。大量的研究结果表明，切削状态的每个微小变化都能通过切削力的变化反映出来，检测切削力是目前国内外研究与应用最多的监测方法之一，但这些方法在使用时或多或少的要改变机床的原有部件，影响机床的系统特性，特别是对高精度数控机床影响更大。
然而，切削力的准确测量依赖于测力仪本身的性能。本文基于YDC-Ⅲ89压电式动态车削测力仪在测试过程中失真信号的监测与分析，采用有限元法对测力仪结构进行了热结构分析，得出其在切削热作用下该测力仪的温度场分布及应力场分布，同时采用模拟实验的方法对有限元分析结果进行了验证。从而得出测力仪在动态测试时，切削热对其性能的影响规律。两种方法均证明了切削热是压电车削测力仪动态测试信号失真的主要原因。
为了消除切削热对测力仪工作状态的影响，本文分别从压电原理应用和预紧方式两方面对测力仪结构进行了设计。从压电原理应用角度考虑，设计了一种双弹性环结构，并对该测力仪结构中的关键尺寸进行了有限元优化；从预紧方式考虑，在对压电式铣削测力仪的研究基础上，成功研制了一种新型的分体式测力仪，该结构的突出特点是：测力仪主要由刀头、传感器、刀杆等几本分组成，便于拆装。并可大大减少切削热对测力仪性能的影响。
最后，对分体式测力仪进行了静态、动态标定实验以及切削实验，实验结果表明该车削测力传感器大大改进了测力仪的性能，完全可以用于实际测量，传感器的技术指标全面达到CIRP-STCC规定的测力仪标准。
The monitor technology is higher requested in cutting process which develops to high speed, high precision and automatization. It is more and more important to monitor and control cutting process in order to make the automatization equipment work under best condition, ensure the quality of machining and improve manufacturing efficiency. Much study on cutting process indicates that every small change of cutting state can be reflected via the change of cutting force. Measuring cutting force is one of the most common monitoring methods in domestic and external. Some parts of machine tool will be changed which will influence the characteristic of machine tool, especially high precision NC machine tool.
However,the cutting forces are measured which rely on its own performance of dynamometer.this paper Bases on Dynamometer of YDC-III89 on Cutting distortion signal monitoring and analying in the process of testing,using finite element method to analyse the performance of dynamometer in thermal and structure,and educing the distributing of temperature field and stress field. Furthermore,this paper also validates finite element analysis results in virtue of simulation experiment and gained the influencing rule of cutting heat in the end.the results proved the influence of cutting heat to Dynamometer of Piezoelectricity on Cutting.
In order to eliminate the influence of cutting heat, the structure of dynamometer is changed through the application principle of piezoelectric materials and the way of pretension.Finite element method is used to analyse the stiffness of the new designed dynamometer with two elastic rings and optimize the key dimensions. Another new dynamometer which is made up of cutter head,sensors and cutter holder. This structure is easy to assemble and avoids the influence of cutting heat.
The results of experiment of static demarcation,dynamic demarcation and cutting test show that the new design dynamometer has fully improved the performance of dynamometer and reached dynamic dynamometer's standard which is stipulated by CIRP-STCC.
然而，切削力的准确测量依赖于测力仪本身的性能。本文基于YDC-Ⅲ89压电式动态车削测力仪在测试过程中失真信号的监测与分析，采用有限元法对测力仪结构进行了热结构分析，得出其在切削热作用下该测力仪的温度场分布及应力场分布，同时采用模拟实验的方法对有限元分析结果进行了验证。从而得出测力仪在动态测试时，切削热对其性能的影响规律。两种方法均证明了切削热是压电车削测力仪动态测试信号失真的主要原因。
为了消除切削热对测力仪工作状态的影响，本文分别从压电原理应用和预紧方式两方面对测力仪结构进行了设计。从压电原理应用角度考虑，设计了一种双弹性环结构，并对该测力仪结构中的关键尺寸进行了有限元优化；从预紧方式考虑，在对压电式铣削测力仪的研究基础上，成功研制了一种新型的分体式测力仪，该结构的突出特点是：测力仪主要由刀头、传感器、刀杆等几本分组成，便于拆装。并可大大减少切削热对测力仪性能的影响。
最后，对分体式测力仪进行了静态、动态标定实验以及切削实验，实验结果表明该车削测力传感器大大改进了测力仪的性能，完全可以用于实际测量，传感器的技术指标全面达到CIRP-STCC规定的测力仪标准。
The monitor technology is higher requested in cutting process which develops to high speed, high precision and automatization. It is more and more important to monitor and control cutting process in order to make the automatization equipment work under best condition, ensure the quality of machining and improve manufacturing efficiency. Much study on cutting process indicates that every small change of cutting state can be reflected via the change of cutting force. Measuring cutting force is one of the most common monitoring methods in domestic and external. Some parts of machine tool will be changed which will influence the characteristic of machine tool, especially high precision NC machine tool.
However,the cutting forces are measured which rely on its own performance of dynamometer.this paper Bases on Dynamometer of YDC-III89 on Cutting distortion signal monitoring and analying in the process of testing,using finite element method to analyse the performance of dynamometer in thermal and structure,and educing the distributing of temperature field and stress field. Furthermore,this paper also validates finite element analysis results in virtue of simulation experiment and gained the influencing rule of cutting heat in the end.the results proved the influence of cutting heat to Dynamometer of Piezoelectricity on Cutting.
In order to eliminate the influence of cutting heat, the structure of dynamometer is changed through the application principle of piezoelectric materials and the way of pretension.Finite element method is used to analyse the stiffness of the new designed dynamometer with two elastic rings and optimize the key dimensions. Another new dynamometer which is made up of cutter head,sensors and cutter holder. This structure is easy to assemble and avoids the influence of cutting heat.
The results of experiment of static demarcation,dynamic demarcation and cutting test show that the new design dynamometer has fully improved the performance of dynamometer and reached dynamic dynamometer's standard which is stipulated by CIRP-STCC.
引文
[1] 刘培德，胡荣生，孙宝元．切削力学新篇(学术专著)．第一版．大连理工大学出版社
[2] 孙宝元，杨宝清．传感器及其应用手册．第一版．北京：机械工业出版社，2004
[3] Quartz Torque dynamometer. Kistler 9277 Specification
[4] 孙宝元，钱敏，张军．压电式切削测力仪研发的新进展．第七届年会暨国际先进制造技术研讨会论文集，649．
[5] 孙宝元，张贻恭．压电石英力传感器及动态切削测力仪．第一版．北京：计量出版社，1985．
[6] W. Voigt. Lehrbuch der Kristallphysik. Teubner Leipzig. 1910.
[7] W. G. Cady. Piezoelectricity. New York: Dover Book Pub.1964.
[8] W. P. Mason. Crystal Physics of Interaction Processes.New York: Academic Press, 1966.
[9] W. P. Mason. Piezoelectricity, its history and applications. Acoustical Society of America, 1981, 70(6):1561-1566.
[10] 孙宝元，钱敏，张军．压电式传感器与测力仪研发回顾与展望．大连理工大学学报．2001，41 (2)：127-134．
[11] 孙宝元，张贻恭，王子江．一种简便实用的压电石英晶体刀杆式三向车削测力仪．大连工学院学报．1983，21(2)：85-94．
[12] 李晓鹏．整体式压电磨削测力平台的结构优化设计．大连理工大学硕士学位论文．2005．
[13] Juretschke H J. Crystal physics. Benjamin:Massachussetts, 1974.
[14] 陈纲，廖理几．晶体物理学基础．第一版．北京：科学出版社，1992．
[15] 张福学．现代压电学．第一版．北京：科学出版社，2002．
[16] 闰西林．阮永丰等．晶体物理学．第一版．北京：电子工业出版社，1995．
[17] 秦自楷．压电石英晶体．第一版．北京：国防工业出版社，1980．
[18] 钱敏，孙宝元．压电测力平台中传感器新的配置原则．第四届全国敏感元件与传感器学术会议，1995，5．
[19] 邓凡平．ANSYS 10.0有限元分析自学手册．第一版，人民邮电出版社，2007．
[20] 李维特，黄保海，毕仲波等．热应力理论分析及应用．北京：中国电力出版社，2004．
[21] 孙宝元，张贻恭，杨华敏．压电式动态切削测力仪(上，下)．机床．1975．
[22] 刘晓玲．新型压电动态切削测力仪的结构设计与优化分析．大连理工大学硕士学位论文．2005．
[23] 孙宝元．三向压电式车削测力仪结构优化设计．机械工程学报，1990．
[24] ANSYS, Inc. ANSYS Structural Analysis Guide Release 5.4. Third Edition. SAP, IP Inc., 1997.
[25] 于虎．四向压电钻削测力仪的研制及其实验研究．大连理工大学硕士学位论文．2005．
[26] Standards Committee of the IEEE Ultrasonics, Ferroelectrics and Frequency Control Society, IEEE Standard on Piezoelectricity. 1987, 10
[27] 张贻恭，孙宝元．YDS-Ⅲ79B，YDS-Ⅲ79K型石英晶体三维力传感器的设计与研制．大连工学院学报．1981，20(1)：1-9．
[28] 邱宣怀．机械设计．第四版．北京．高等教育出版社，2004．
[29] 钱敏，孙宝元一种新型压电式磨铣削测力仪的优化设计，机械工业出版社，中国高校切削与先进制造研究会第六届年会1999．5论文集．
[30] 张贻恭，孙宝元，罗胜初．SDJ-80A三维力传感器精密标定夹具的设计．大连工学院学报，1981，20(2)：28-83．
[31] 孙宝元，王吉军，钱敏．压电石英晶片灵敏度分布规律及其跟踪检测．大连理工大学学报．1990．：30(1)：59-64．
[32] 戴恒震，孙宝元，李万全，高长银．一种多功能测力仪加载器，现代机械，2003，6：45-46．
[33] 许靖中，谢峰，王从周．三向压电晶体力传感器的研究．安徽工学院学报，1989．8．
[34] Scientific Technical Committees of CIRP-STCC. Reports of the scientific technicalcommittees of CIRP-STCC:recommendation of calibration and operation of machine-tool dynamometer[J]. CIRP, 1974, 23 (2) :295-306.
[35] 徐科军编．传感器动态特性的实用研究方法．合肥：中国科学技术大学出版社，1999(4)：21-28．
[36] 蔡礼君．切削测力仪的动态误差．机械工程学报．2000，20(4)：78-82．
[37] 王维贵编．动态压力测量原理及方法．北京：中国计量出版社，1976．
[38] Roger W. Ward. The Constants of alpha quartz. 14th piezoelectric devices conference and exhibition, 1992.
[39] Standards Committee of the IEEE Ultrasonics, Ferroelectrics and Frequency Control Society, IEEE Standard on Piezoelectricity. 1987, 10.
[2] 孙宝元，杨宝清．传感器及其应用手册．第一版．北京：机械工业出版社，2004
[3] Quartz Torque dynamometer. Kistler 9277 Specification
[4] 孙宝元，钱敏，张军．压电式切削测力仪研发的新进展．第七届年会暨国际先进制造技术研讨会论文集，649．
[5] 孙宝元，张贻恭．压电石英力传感器及动态切削测力仪．第一版．北京：计量出版社，1985．
[6] W. Voigt. Lehrbuch der Kristallphysik. Teubner Leipzig. 1910.
[7] W. G. Cady. Piezoelectricity. New York: Dover Book Pub.1964.
[8] W. P. Mason. Crystal Physics of Interaction Processes.New York: Academic Press, 1966.
[9] W. P. Mason. Piezoelectricity, its history and applications. Acoustical Society of America, 1981, 70(6):1561-1566.
[10] 孙宝元，钱敏，张军．压电式传感器与测力仪研发回顾与展望．大连理工大学学报．2001，41 (2)：127-134．
[11] 孙宝元，张贻恭，王子江．一种简便实用的压电石英晶体刀杆式三向车削测力仪．大连工学院学报．1983，21(2)：85-94．
[12] 李晓鹏．整体式压电磨削测力平台的结构优化设计．大连理工大学硕士学位论文．2005．
[13] Juretschke H J. Crystal physics. Benjamin:Massachussetts, 1974.
[14] 陈纲，廖理几．晶体物理学基础．第一版．北京：科学出版社，1992．
[15] 张福学．现代压电学．第一版．北京：科学出版社，2002．
[16] 闰西林．阮永丰等．晶体物理学．第一版．北京：电子工业出版社，1995．
[17] 秦自楷．压电石英晶体．第一版．北京：国防工业出版社，1980．
[18] 钱敏，孙宝元．压电测力平台中传感器新的配置原则．第四届全国敏感元件与传感器学术会议，1995，5．
[19] 邓凡平．ANSYS 10.0有限元分析自学手册．第一版，人民邮电出版社，2007．
[20] 李维特，黄保海，毕仲波等．热应力理论分析及应用．北京：中国电力出版社，2004．
[21] 孙宝元，张贻恭，杨华敏．压电式动态切削测力仪(上，下)．机床．1975．
[22] 刘晓玲．新型压电动态切削测力仪的结构设计与优化分析．大连理工大学硕士学位论文．2005．
[23] 孙宝元．三向压电式车削测力仪结构优化设计．机械工程学报，1990．
[24] ANSYS, Inc. ANSYS Structural Analysis Guide Release 5.4. Third Edition. SAP, IP Inc., 1997.
[25] 于虎．四向压电钻削测力仪的研制及其实验研究．大连理工大学硕士学位论文．2005．
[26] Standards Committee of the IEEE Ultrasonics, Ferroelectrics and Frequency Control Society, IEEE Standard on Piezoelectricity. 1987, 10
[27] 张贻恭，孙宝元．YDS-Ⅲ79B，YDS-Ⅲ79K型石英晶体三维力传感器的设计与研制．大连工学院学报．1981，20(1)：1-9．
[28] 邱宣怀．机械设计．第四版．北京．高等教育出版社，2004．
[29] 钱敏，孙宝元一种新型压电式磨铣削测力仪的优化设计，机械工业出版社，中国高校切削与先进制造研究会第六届年会1999．5论文集．
[30] 张贻恭，孙宝元，罗胜初．SDJ-80A三维力传感器精密标定夹具的设计．大连工学院学报，1981，20(2)：28-83．
[31] 孙宝元，王吉军，钱敏．压电石英晶片灵敏度分布规律及其跟踪检测．大连理工大学学报．1990．：30(1)：59-64．
[32] 戴恒震，孙宝元，李万全，高长银．一种多功能测力仪加载器，现代机械，2003，6：45-46．
[33] 许靖中，谢峰，王从周．三向压电晶体力传感器的研究．安徽工学院学报，1989．8．
[34] Scientific Technical Committees of CIRP-STCC. Reports of the scientific technicalcommittees of CIRP-STCC:recommendation of calibration and operation of machine-tool dynamometer[J]. CIRP, 1974, 23 (2) :295-306.
[35] 徐科军编．传感器动态特性的实用研究方法．合肥：中国科学技术大学出版社，1999(4)：21-28．
[36] 蔡礼君．切削测力仪的动态误差．机械工程学报．2000，20(4)：78-82．
[37] 王维贵编．动态压力测量原理及方法．北京：中国计量出版社，1976．
[38] Roger W. Ward. The Constants of alpha quartz. 14th piezoelectric devices conference and exhibition, 1992.
[39] Standards Committee of the IEEE Ultrasonics, Ferroelectrics and Frequency Control Society, IEEE Standard on Piezoelectricity. 1987, 10.
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