精车大螺距螺杆加工系统的稳定性
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摘要
高进给速度精车大螺距螺杆加工过程中,随着旋转螺纹件与刀具相对接触关系的实时变化、刀具磨损量的动态演变和工件材料去除导致的质量变化,加工系统的动力学特性呈现时变特性,研究其稳定性也就具有重要意义。首先结合精车削大螺距螺杆动力学模型,分别利用频域法和全离散时域法,提出一种适用于大螺距螺纹件的车削稳定域预估方法,并进行实验验证;然后在时域法基础上,考虑过程阻尼的影响,研究了不同刀具磨损情况对精车大螺距螺杆切削加工稳定性的影响,并验证测量结果与预测规律相吻合。研究结果表明:精车大螺距螺杆稳定性预测优先选用时域法;极限切深随后刀面磨损量增大而呈现出上升的趋势;选用转速分别为10r/min和25r/min,切深8mm,轴向进刀量0.05mm加工参数进行加工时,能获得基本符合工程实际要求的成品件。本文研究成果为高进给车削工艺参数优选奠定理论基础,同时丰富和发展以大螺距螺杆为代表的大型装备关键零部件的高进给加工理论并推进其工程应用。
In high-feed turning process,the dynamic characteristics of the machining system exhibit time-varying with real-time changes in the relative contact relationship between the rotating workpiece,the dynamic evolution of the tool wear and the cutting tool,and the quality change caused due to material removal.Combined with the dynamic model of large-pitch thread,using the zero-order frequency domain method and the improved full-discrete time-domain method,a cutting stability prediction method for turning large-pitch thread was proposed and experimentally verified.Based on the time-domain method,considering the influence of process damping,the influence of different tool wear conditions on the cutting stability of the large-pitch thread during finish turning process was investigated in this study,and consistency of the experimental measurements with the predicted results was verified.It is concluded that the ultimate cutting depth increases with the increase in tool wear;the machining parameters,such as the spindle speed is in the range 10-25 r/min,cutting depth is 8 mm,and axial feed amount is 0.05 mm,which should be given priority in the process planning of trapezoidal screw with large pitch.The results obtained provide the theoretical basis for the optimization of large-pitch thread turning process parameters.The enhancement and advancement of highspeed feed processing theory and high-efficiency machining technology is of great importance for the development of large equipment key components represented by large-pitch thread.
In high-feed turning process,the dynamic characteristics of the machining system exhibit time-varying with real-time changes in the relative contact relationship between the rotating workpiece,the dynamic evolution of the tool wear and the cutting tool,and the quality change caused due to material removal.Combined with the dynamic model of large-pitch thread,using the zero-order frequency domain method and the improved full-discrete time-domain method,a cutting stability prediction method for turning large-pitch thread was proposed and experimentally verified.Based on the time-domain method,considering the influence of process damping,the influence of different tool wear conditions on the cutting stability of the large-pitch thread during finish turning process was investigated in this study,and consistency of the experimental measurements with the predicted results was verified.It is concluded that the ultimate cutting depth increases with the increase in tool wear;the machining parameters,such as the spindle speed is in the range 10-25 r/min,cutting depth is 8 mm,and axial feed amount is 0.05 mm,which should be given priority in the process planning of trapezoidal screw with large pitch.The results obtained provide the theoretical basis for the optimization of large-pitch thread turning process parameters.The enhancement and advancement of highspeed feed processing theory and high-efficiency machining technology is of great importance for the development of large equipment key components represented by large-pitch thread.
引文
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[18]吴石,刘献礼,宋盛罡,等.铣刀磨损对铣削稳定性及表面位置误差的影响[J].振动、测试与诊断,2015,35(4):763-769,803.WU SH,LIU X L,SONG SH G,et al..The influence of wear loss of milling cutter on milling stability and surface location error[J].Journal of Vibration,Measurement&Diagnosis,2015,35(4):763-769,803.(in Chinese)
[19]MENEZES J,RUBEO M A,KIRAN K.Productivity progression with tool wear in titanium milling[J].Procedia Manufacturing,2016,5:427-441.
[20]刘宇,王振宇,杨慧刚,等.微铣削中考虑时变切削力系数的颤振稳定性预测[J].振动与冲击,2018(3):160-166.LIU Y,WANG ZH Y,YANG H G,et al..Chatter stability prediction for micro-milling processes with time-varying cutting force coefficients[J].Journal of Vibration and Shock,2018(3):160-166.(in Chinese)
[21]JIANG B,ZHAO J,ZHENG M,et al..Transient cutting force model in turning large-pitch external thread[J].The International Journal of Advanced Manufacturing Technology,2018,98(1-4):1-16.
[22]MINIS I,YANUSHEVSKY R.A new theoretical approach for the prediction of machine tool chatter in milling[J].Journal of Engineering for Industry,1993,115(1):1-8.
[23]HALE J K,LUNEL S M V.Introduction to functional differential equations[J].Applied Mathematical Sciences,1995.
[2]DING Y,ZHU L M,ZHANG X J.Second-order full-discretization method for milling stability prediction[J].International Journal of Machine Tools and Manufacture,2010,50(10):926-932.
[3]DING Y,ZHU L M,ZHANG X J.A full-discretization method for prediction of milling stability[J].International Journal of Machine Tools and Manufacture,2010,50(5):502-509.
[4]刘成颖,张洁,刘巍,等.基于步长控制的铣削稳定性预测全离散法[J].组合机床与自动化加工技术,2017(12):59-61.LIU CH Y,ZHANG J,LIU W,et al..A full-discretization method for milling stability predication based on time-step control[J].Modular Machine Tool&Automatic Manufacturing Technique,2017(12):59-61.(in Chinese)
[5]汪勇.轴类零件正交车铣加工稳定性建模与分析[D].武汉:华中科技大学,2014.WANG Y.Stability Modeling and Analysis for Orthogonal Turn-milling of Shaft Parts[D].Wuhan:Graduate University of the Huazhong University of Science and Technology,2014.(in Chinese)
[6]张小俭.柔性结构铣削时滞工艺系统的稳定性理论与实验研究[D].武汉:华中科技大学,2012.ZHANG X J.Theoretical and Experimental Research of Time-delay System in the Flexible Part Milling[D].Wuhan:Graduate University of the Huazhong University of Science and Technology,2012.(in Chinese)
[7]李明震.基于完全离散化方法的切削过程稳定性预测研究[D].武汉:华中科技大学,2013.LI M ZH.A Thesis Submitted in Partial Fulfillment of the Requirements for the Degree for Doctor of Philosophy in Engineering[D].Wuhan:Graduate University of the Huazhong University of Science and Technology,2013.(in Chinese)
[8]BUDAK E,ALTINTAS Y.Analytical prediction of chatter stability in milling-Part II:General formulation to common milling systems[J].Journal of Dynamic Systems,Measurement,and Control,1998,120(1):31-36.
[9]BUDAK E,ALTINTAS Y.Analytical prediction of chatter stability in milling-Part I:General formulation[J].Journal of Dynamic Systems,Measurement,and Control,1998.
[10]ALTINTAS Y,BUDAK E.Analytical prediction of stability lobes in milling[J].CIRP Annals-Manufacturing Technology,1995,44(1):357-362.
[11]MERDOL S D,ALTINTAS Y.Multi frequency solution of chatter stability for low immersion milling[J].Journal of Manufacturing Science and Engineering,2004,126(3):459.
[12]WAN M,MA Y C,ZHANG W H.Study on the construction mechanism of stability lobes in milling process with multiple modes[J].The International Journal of Advanced Manufacturing Technology,2015,79(1-4):589-603.
[13]刘宇,刘亚超,张义民.车削颤振稳定性预测软件研究与开发[J].东北大学学报(自然科学版),2016,37(3):373-377.LIU Y,LIU Y CH,ZHANG Y M.Research and development of the prediction software for turning chatter stability[J].Journal of Northeastern University(Natural Science),2016,37(3):373-377.(in Chinese)
[14]王波.铣削颤振稳定性频域方法分析研究[D].沈阳:东北大学,2014.WANG B.Analysis of the Chatter Stability in Frequency Domain Theory[D].Shenyang:Graduate University of the Northeastern University,2014.(in Chinese)
[15]徐东晓.齿圈车削加工系统颤振稳定性研究[D].北京:北京理工大学,2015.XU D X.Study on Shatter Stability of Ring Gear Turning Process[D].Beijing:Graduate University of the Beijing Institute of Technology,2015.(in Chinese)
[16]RICHARD Y C,STEVEN Y L.Chatter stability of a slender cutting tool in turning with tool wear effect[J].International Journal of Machine Tools and Manufacture,38(4):1998,315-327.
[17]GUTNICHENKO O,BUSHLYA V,ZHOU J.Influence of cutting speed and tool wear on vibrations and process stability when turning Inconel718with PCBN tools[J].International Journal of Manufacturing Research,2014,9(2):173-193.
[18]吴石,刘献礼,宋盛罡,等.铣刀磨损对铣削稳定性及表面位置误差的影响[J].振动、测试与诊断,2015,35(4):763-769,803.WU SH,LIU X L,SONG SH G,et al..The influence of wear loss of milling cutter on milling stability and surface location error[J].Journal of Vibration,Measurement&Diagnosis,2015,35(4):763-769,803.(in Chinese)
[19]MENEZES J,RUBEO M A,KIRAN K.Productivity progression with tool wear in titanium milling[J].Procedia Manufacturing,2016,5:427-441.
[20]刘宇,王振宇,杨慧刚,等.微铣削中考虑时变切削力系数的颤振稳定性预测[J].振动与冲击,2018(3):160-166.LIU Y,WANG ZH Y,YANG H G,et al..Chatter stability prediction for micro-milling processes with time-varying cutting force coefficients[J].Journal of Vibration and Shock,2018(3):160-166.(in Chinese)
[21]JIANG B,ZHAO J,ZHENG M,et al..Transient cutting force model in turning large-pitch external thread[J].The International Journal of Advanced Manufacturing Technology,2018,98(1-4):1-16.
[22]MINIS I,YANUSHEVSKY R.A new theoretical approach for the prediction of machine tool chatter in milling[J].Journal of Engineering for Industry,1993,115(1):1-8.
[23]HALE J K,LUNEL S M V.Introduction to functional differential equations[J].Applied Mathematical Sciences,1995.