磨削振动控制系统设计与开发
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摘要
磨削常做为工件加工的最后一道工序,其几何误差和表面完整性等加工质量要求很高,磨削振动是影响加工质量的重要因素,众多研究者对探测和避免此动态过程进行了研究以消除砂轮磨损和提高工件加工质量,运用砂轮与工件间周期性的分离或者跟随工件速度周期性的振动来实现磨削振动控制的可行方法尚未可见。本文作者对磨削振动进行了研究,基于对磨削低碳钢和硬化钢的磨削力进行实验检测,设计了一套闭环控制器,实现对工件振动的控制。并通过普通磨削过程进行验证,结果显示,此控制器对磨削振动有较好的改善作用。
Grinding is usually the last operation applied to the workpiece and hence deviations of the geometry and surface finish are not allowed because even finishing operation generally do correct workpiece geometry. Therefore it is imperative to get this process designed and carried out as accurate as possible to hold all required sizes and geometry of the part. However, in grinding vibration(Chatter) between wheel and workpiece poses challenges in maintaining process requirements. A wide range of investigations have been carried out to detect and avoid this dynamic phenomenon that affects wheel/workpiece interaction leading to uneven wear and poor workpiece quality. A possible method to prevent this type of chatter is to apply a periodic disengagement of the wheel from the workpiece or periodic variation of the work speed. The work presented was an investigation into vibratory grinding where a closed loop controller was designed to control the oscillation of the workpiece. The controller design was given along with experimental results illustrating grinding forces for mild and hardened steel. A comparison with conventional shallow grinding shows that the vibratory grinding has a better performance.
Grinding is usually the last operation applied to the workpiece and hence deviations of the geometry and surface finish are not allowed because even finishing operation generally do correct workpiece geometry. Therefore it is imperative to get this process designed and carried out as accurate as possible to hold all required sizes and geometry of the part. However, in grinding vibration(Chatter) between wheel and workpiece poses challenges in maintaining process requirements. A wide range of investigations have been carried out to detect and avoid this dynamic phenomenon that affects wheel/workpiece interaction leading to uneven wear and poor workpiece quality. A possible method to prevent this type of chatter is to apply a periodic disengagement of the wheel from the workpiece or periodic variation of the work speed. The work presented was an investigation into vibratory grinding where a closed loop controller was designed to control the oscillation of the workpiece. The controller design was given along with experimental results illustrating grinding forces for mild and hardened steel. A comparison with conventional shallow grinding shows that the vibratory grinding has a better performance.
引文
[1]MORIWAKI T,SHAMOTO E.Ultra-precision Diamond Turning of Stainless Steel by Applying Ultrasonic Vibration[J].Journal of the Japan Society for Precision Engineering,1991,57(11):1983-1988.
[2]BABITSKY V I,KALASHNIKOV A N,MEADOWS A,et al.Ultrasonically Assisted Turning of Aviation Materials[J].Journal of Materials Processing Technology,2003,132(1):157-167.
[3]CERNIWAY M A.Elliptical Diamond Milling:Kinematics,Force and Tool Wear[D].Carolina:North Carolina State University,2001.
[4]BREHL D E,DOW T A,GARRAD K,et al.Micro-structure Fabrication Using Elliptical Vibration-Assisted Machining(EVAM)1[C]//Proceedings of ASPE,2006,39:511-514.
[5]ALBIZURIA J,FERNANDESB M H,GARITAONANDIAB I,et al.An Active System of Reduction of Vibrations in a Centreless Grinding Machine Using Piezoelectric Actuators[J].International Journal of Machine Tools & Manufacture,2007,47(10):1607-1614.
[6]TAWAKOLI T,AZAHOUSHANG B.Influence of Ultrasonic Vibrations on Dry Grinding of Soft Steel[J].International Journal of Machine Tools & Manufacture,2008,48(14):1585-1591.
[7]LIANG Z,WU Y,WANGA X,et al.A New Two Dimensional Ultrasonic Assisted Grinding(2D-UAG) Method and Its Fundamental Performance in Monocrystal Silicon Machining[J].International Journal of Machine Tools & Manufacture,2010,50(8):728-736.
[8]TSIAKOUMIS V I.An Investigation into Vibration Assisted Machining,Application to Surface Grinding Processes[D].Liverpool:Liverpool John Moores University,2011.
[9]BATAKO A D L,TSIAKOUMIS V.An Experimental Investigation into Resonance Dry Grinding of Hardened Steel and Nickel Alloys with Element of MQL[J].The International Journal Advanced Manufacuring Technology,2015,77(1/2/3/4):27-41.
[10]MICHAEL E H C,ANDRE B D.Development of Control System for Vibratory Grinding Process[J].Procedia Engineering,2017,174:1093-1099.
[2]BABITSKY V I,KALASHNIKOV A N,MEADOWS A,et al.Ultrasonically Assisted Turning of Aviation Materials[J].Journal of Materials Processing Technology,2003,132(1):157-167.
[3]CERNIWAY M A.Elliptical Diamond Milling:Kinematics,Force and Tool Wear[D].Carolina:North Carolina State University,2001.
[4]BREHL D E,DOW T A,GARRAD K,et al.Micro-structure Fabrication Using Elliptical Vibration-Assisted Machining(EVAM)1[C]//Proceedings of ASPE,2006,39:511-514.
[5]ALBIZURIA J,FERNANDESB M H,GARITAONANDIAB I,et al.An Active System of Reduction of Vibrations in a Centreless Grinding Machine Using Piezoelectric Actuators[J].International Journal of Machine Tools & Manufacture,2007,47(10):1607-1614.
[6]TAWAKOLI T,AZAHOUSHANG B.Influence of Ultrasonic Vibrations on Dry Grinding of Soft Steel[J].International Journal of Machine Tools & Manufacture,2008,48(14):1585-1591.
[7]LIANG Z,WU Y,WANGA X,et al.A New Two Dimensional Ultrasonic Assisted Grinding(2D-UAG) Method and Its Fundamental Performance in Monocrystal Silicon Machining[J].International Journal of Machine Tools & Manufacture,2010,50(8):728-736.
[8]TSIAKOUMIS V I.An Investigation into Vibration Assisted Machining,Application to Surface Grinding Processes[D].Liverpool:Liverpool John Moores University,2011.
[9]BATAKO A D L,TSIAKOUMIS V.An Experimental Investigation into Resonance Dry Grinding of Hardened Steel and Nickel Alloys with Element of MQL[J].The International Journal Advanced Manufacuring Technology,2015,77(1/2/3/4):27-41.
[10]MICHAEL E H C,ANDRE B D.Development of Control System for Vibratory Grinding Process[J].Procedia Engineering,2017,174:1093-1099.