阻尼动力减振镗杆动态特性仿真与优化设计研究
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摘要
深孔加工由于其特殊的加工环境,使镗杆杆体的尺寸和形状都要受到一定的限制,造成镗杆的刚度较低,特别是在镗杆的长径比较大的情况下,镗杆的刚度会更小,导致切削中振动加剧,严重影响加工质量,甚至使加工无法正常进行。如何减小深孔加工过程中的振动已成为迫待解决的问题。
本文在总结了国内外对减振镗杆的减振技术、结构设计、试验方法和减振效果分析的基础上,利用多柔体动力学仿真技术对阻尼动力减振镗杆系统进行建模、仿真、优化研究,并根据仿真优化结果进行阻尼动力减振镗杆的实际设计和研制,其主要研究内容如下:
在阻尼动力减振镗杆结构特点和减振特性研究基础上,利用材料力学和振动力学,推导镗杆的等效刚度和等效质量的计算公式,建立阻尼动力减振镗杆的数学简化模型,并分析镗杆减振系统的减振原理及振动特性,为镗杆减振系统的进一步研究提供理论依据。
利用ADAMS和ANSYS软件对阻尼动力减振镗杆进行多柔体动力学仿真,通过理论结果与仿真结果对比验证模型的正确性。利用ADAMS软件的振动模块分析减振系统中环形橡胶径向刚度系数和阻尼液等效粘性阻尼系数对镗杆动态特性的影响。对阻尼动力减振镗杆多柔体动力学模型进行频域内优化分析,得出了减振系统各参数的最优值。通过优化后仿真分析发现系统频域最大响应值降为优化前三分之一,系统的抗振性能得到明显改善。
利用ANSYS软件建立环形橡胶有限元参数化模型,通过函数逼近和梯度寻优的优化算法实现环形橡胶径向刚度与各设计参数之间的快速换算。分析内外圆柱面半径与轴向长度对环形橡胶径向刚度的影响,为环形橡胶的设计提供依据。利用流体力学相关知识,推导出阻尼动力减振镗杆中阻尼液等效粘度阻尼系数与运动粘度之间的估算公式,为实际设计中阻尼液的选用提供依据。
为了验证理论计算和仿真结果的正确性,采用SA-78型双通道FFT信号分析仪在CW6163型普通车床上对阻尼动力减振镗杆进行振动特性实验。通过实验发现实验值和仿真值吻合较好,验证所建立仿真模型的正确性。普通镗杆与阻尼动力减振镗杆的实际加工对比实验表明阻尼动力减振镗杆的抗振性得到了大幅提高。
通过对阻尼动力减振镗杆设计与动态特性仿真研究,给出阻尼动力减振镗杆系统的优化设计方案,为镗杆的设计和研制奠定了基础,为镗杆减振技术的研究提供了新的分析方法。
The size and shape of the boring bar are restricted because of the special machining condition in the deep-hole turning. This produces the low stiffness of the boring bar which will become lower especially with large length to diameter ratio. The vibration in the cutting will be aggravated and the machining quality will be badly affected. More dramatically, the machining can not be on the rails due to the lower stiffness. How to reduce the vibration in the deep-hole turning has become an urgent problem.
In this thesis, based on the summary of vibration technology, structural design, test methods and vibration absorption effect analysis at home and abroad of vibration absorption boring bar, the simulation model of the dynamical vibration absorption boring bar with damping is established, simulated and optimized by using the flexible multi-body dynamics simulation technique. On the basis of the simulation results, the dynamical vibration absorption boring bar with damping has been designed and manufactured. The main content of this thesis includes the following parts:
Based on the research of structural features and vibration absorption characteristics of dynamical vibration absorption boring bar with damping, the knowledge of mechanics of materials and mechanics of vibration is used to derive the formula of the equivalent stiffness and equivalent mass of boring bar, establish the simplified mathematical model, and analyze the vibration absorption principle and vibration characteristics of the dynamical vibration absorption boring bar with damping. This provides the theoretical basis for further study on vibration absorption system of boring bar.
The software of ADAMS and ANSYS is used to build up the flexible multi- body dynamics simulation model of the dynamical vibration absorption boring bar with damping. And the comparison between theoretical results and simulation results verifies the validity of the model. The influence of the radial stiffness coefficient of rubber brushes and the equivalent viscous damping coefficient of damping fluid on the vibration system is discussed by using the vibration analyses module of ADAMS. The flexible multi-body dynamics model of the dynamical vibration absorption boring bar with damping has been simulated, optimized and analyzed in frequency domain. And optimized parameters are obtained finally. Simulation analysis of optimized system shows the maximal frequency response value of the system reduces to one-third of that of original system. And the vibration resistance of the system is vastly improved.
The finite element model of rubber bush is built up by using the software of ANSYS. Fast conversion between the radial Stiffness and design parameters of rubber bush is achieved with function approximation and gradient optimization algorithm. The influence of inner and outer radii and axial length on the radial stiffness of rubber bush is analyzed, which provides guidance for the design of the rubber bush. Based on the knowledge of fluid dynamics, an estimated formula between the equivalent viscosity coefficient and the movement viscosity coefficient of damping fluid is given. This provides guidance for the selection of damping fluid.
In order to verify the correctness of theoretical calculation and simulation results, 2ch FFT analyzer SA-78 is used to test the vibration characteristic of the dynamical vibration absorption boring bar with damping on lathe CW6163. Experiments show that experimental values and simulation values are in good agreement, which verifies the correctness of the simulation model. The comparative test of the common boring bar and the dynamical vibration absorption boring bar with damping in actual boring processing indicates that the vibration resistance of the bar is vastly improved.
Through design and dynamic characteristics simulation of the dynamical vibration absorption boring bar with damping, the optimization design proposal of it is given, which lays the foundation for the design and development of boring bar and provides a new analysis method for the research on the vibration technology of boring bar.
本文在总结了国内外对减振镗杆的减振技术、结构设计、试验方法和减振效果分析的基础上,利用多柔体动力学仿真技术对阻尼动力减振镗杆系统进行建模、仿真、优化研究,并根据仿真优化结果进行阻尼动力减振镗杆的实际设计和研制,其主要研究内容如下:
在阻尼动力减振镗杆结构特点和减振特性研究基础上,利用材料力学和振动力学,推导镗杆的等效刚度和等效质量的计算公式,建立阻尼动力减振镗杆的数学简化模型,并分析镗杆减振系统的减振原理及振动特性,为镗杆减振系统的进一步研究提供理论依据。
利用ADAMS和ANSYS软件对阻尼动力减振镗杆进行多柔体动力学仿真,通过理论结果与仿真结果对比验证模型的正确性。利用ADAMS软件的振动模块分析减振系统中环形橡胶径向刚度系数和阻尼液等效粘性阻尼系数对镗杆动态特性的影响。对阻尼动力减振镗杆多柔体动力学模型进行频域内优化分析,得出了减振系统各参数的最优值。通过优化后仿真分析发现系统频域最大响应值降为优化前三分之一,系统的抗振性能得到明显改善。
利用ANSYS软件建立环形橡胶有限元参数化模型,通过函数逼近和梯度寻优的优化算法实现环形橡胶径向刚度与各设计参数之间的快速换算。分析内外圆柱面半径与轴向长度对环形橡胶径向刚度的影响,为环形橡胶的设计提供依据。利用流体力学相关知识,推导出阻尼动力减振镗杆中阻尼液等效粘度阻尼系数与运动粘度之间的估算公式,为实际设计中阻尼液的选用提供依据。
为了验证理论计算和仿真结果的正确性,采用SA-78型双通道FFT信号分析仪在CW6163型普通车床上对阻尼动力减振镗杆进行振动特性实验。通过实验发现实验值和仿真值吻合较好,验证所建立仿真模型的正确性。普通镗杆与阻尼动力减振镗杆的实际加工对比实验表明阻尼动力减振镗杆的抗振性得到了大幅提高。
通过对阻尼动力减振镗杆设计与动态特性仿真研究,给出阻尼动力减振镗杆系统的优化设计方案,为镗杆的设计和研制奠定了基础,为镗杆减振技术的研究提供了新的分析方法。
The size and shape of the boring bar are restricted because of the special machining condition in the deep-hole turning. This produces the low stiffness of the boring bar which will become lower especially with large length to diameter ratio. The vibration in the cutting will be aggravated and the machining quality will be badly affected. More dramatically, the machining can not be on the rails due to the lower stiffness. How to reduce the vibration in the deep-hole turning has become an urgent problem.
In this thesis, based on the summary of vibration technology, structural design, test methods and vibration absorption effect analysis at home and abroad of vibration absorption boring bar, the simulation model of the dynamical vibration absorption boring bar with damping is established, simulated and optimized by using the flexible multi-body dynamics simulation technique. On the basis of the simulation results, the dynamical vibration absorption boring bar with damping has been designed and manufactured. The main content of this thesis includes the following parts:
Based on the research of structural features and vibration absorption characteristics of dynamical vibration absorption boring bar with damping, the knowledge of mechanics of materials and mechanics of vibration is used to derive the formula of the equivalent stiffness and equivalent mass of boring bar, establish the simplified mathematical model, and analyze the vibration absorption principle and vibration characteristics of the dynamical vibration absorption boring bar with damping. This provides the theoretical basis for further study on vibration absorption system of boring bar.
The software of ADAMS and ANSYS is used to build up the flexible multi- body dynamics simulation model of the dynamical vibration absorption boring bar with damping. And the comparison between theoretical results and simulation results verifies the validity of the model. The influence of the radial stiffness coefficient of rubber brushes and the equivalent viscous damping coefficient of damping fluid on the vibration system is discussed by using the vibration analyses module of ADAMS. The flexible multi-body dynamics model of the dynamical vibration absorption boring bar with damping has been simulated, optimized and analyzed in frequency domain. And optimized parameters are obtained finally. Simulation analysis of optimized system shows the maximal frequency response value of the system reduces to one-third of that of original system. And the vibration resistance of the system is vastly improved.
The finite element model of rubber bush is built up by using the software of ANSYS. Fast conversion between the radial Stiffness and design parameters of rubber bush is achieved with function approximation and gradient optimization algorithm. The influence of inner and outer radii and axial length on the radial stiffness of rubber bush is analyzed, which provides guidance for the design of the rubber bush. Based on the knowledge of fluid dynamics, an estimated formula between the equivalent viscosity coefficient and the movement viscosity coefficient of damping fluid is given. This provides guidance for the selection of damping fluid.
In order to verify the correctness of theoretical calculation and simulation results, 2ch FFT analyzer SA-78 is used to test the vibration characteristic of the dynamical vibration absorption boring bar with damping on lathe CW6163. Experiments show that experimental values and simulation values are in good agreement, which verifies the correctness of the simulation model. The comparative test of the common boring bar and the dynamical vibration absorption boring bar with damping in actual boring processing indicates that the vibration resistance of the bar is vastly improved.
Through design and dynamic characteristics simulation of the dynamical vibration absorption boring bar with damping, the optimization design proposal of it is given, which lays the foundation for the design and development of boring bar and provides a new analysis method for the research on the vibration technology of boring bar.
引文
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