高速铣削热缩加长刀杆与刀具配合特性及应用研究
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摘要
大型深型腔注塑模具是大屏幕彩色电视机外壳、电脑显示器、汽车仪表盘、汽车车门内饰件等大型注塑制品的关键制造装备,具有深型腔复杂多型面结构、加工精度和表面质量要求高、制造周期长等特点。当前该类模具的制造过程过分依赖电火花加工与手工抛光与打磨、过分依赖制造者的个人技能与经验等,而使得加工质量难以得到有效保证、整个制造周期大大延长而很难满足日益加剧的市场竞争需要。热缩加长刀杆(Lengthened Shrink-fit Holder-LSFH)与刀具配合因其具有高夹紧强度、高回转平衡性、易于到达和接近深型腔、能满足复杂多型面模具加工对刀具多样性的要求等特点,使其成为实现大型深型腔模具高速、高效高质量铣削加工的重要手段和途径。目前,由于缺乏对LSFH-刀具配合的配合特性、及使用LSFH时的加工参数优选、加工精度控制等方面的深入研究,使其在高速铣削加工中的优势得不到充分发挥。
本文根据大型深型腔模具对适合其高速铣削加工刀具系统的迫切需要,着重从LSFH-刀具配合的接触特性、径向夹持刚度、动力学特性、加工参数优化以及加工变形误差补偿等方面进行深入研究,并通过试验验证了研究过程中所建分析模型的正确性以及加工参数优化与误差补偿方法的有效性和实用性。
作为动力学特性研究和加工变形误差补偿的前提和基础,首先对基于LSFH-刀具配合的高速铣削加工进行了铣削力建模,建立基于反向传播神经网络(Back-Propagation neural network-BPNN)的瞬态铣削力预测模型。通过对实验数据的适当处理,模型把时间参量引入输入向量,从而克服了以往神经网络切削力预测模型只能预测平均切削力而不能预测瞬态切削力的局限;预测模型采用梯度下降动量学习函数和梯度下降动量BP算法训练函数,避免了单纯的梯度下降法使网络训练易收敛到局部最小值的不足。检验结果表明预测模型具有很好的预测精度,高于通常的铣削力解析模型。
在接触特性及径向夹持刚度研究方面,建立了参数化的有限元模型,并给出了一种合理确定模型中接触刚度系数的新方法。研究了初始基本过盈量、配合长度、配合直径以及高速旋转状态下的离心力对等效应力、接触变形与接触压力等的影响。在此基础上首次引入接触变差系数的概念及其计算方法,给出了实现LSFH-刀具配合的合理接触控制的有效方法。研究了不同配合过盈量、夹持长度及主轴转速对径向夹持刚度的影响,并对不同配合过盈量下的临界弯矩进行了理论界定,建立了静态夹持刚度的有效测量评定方法。研究结果表明:所给出的快速确定LSFH-刀具配合接触刚度系数的迭代算法,既能够保证分析结果的准确,又能够保证分析过程的收敛;应根据不同的刀具配合直径进行合理的接触控制;所给出的合理接触控制方法,既能保证刀具夹持的稳定可靠又能提高LSFH的耐用度;在高转速条件下需充分考虑到离心力对径向夹持刚度的削弱作用,以保证在高转速下实现对刀具安全可靠的夹持;静态径向夹持刚度的评定结果验证了所建有限元仿真模型的正确性,分析结果可为LSFH-刀具配合的设计、选用以及生产实际提供依据。
在动力学特性研究方面,首次将有限元分析(Finite Element Analysis-FEA)技术和试验模态分析(Experiment Modal Analysis-EMA)技术结合起来建立LSFH-刀具配合的有限元模型综合验证与修正流程。分析研究了刀具悬伸出LSFH的长度、主轴转速对LSFH-刀具配合的动力特性包括固有频率和振型的影响。在动力特性分析的基础上对给定加工工况下的LSFH-刀具配合进行了瞬态动力学分析,并对实际的瞬态位移响应进行了评定。研究结果表明:刀具悬伸长度对固有频率的影响较为显著;当转速超过一定时应充分考虑高转速对动力特性的影响;在高速加工工况下,要准确求取加工过程中LSFH-刀具配合的受力与变形,必需考虑到LSFH-刀具配合的瞬态动力学特性的影响,这样才能得出与实际加工工况相符合的正确结论。实际评定结果验证了数值仿真结果的正确性,所建立的瞬态动力学分析模型能够满足工程需要,可用于实际铣削加工过程分析。
在使用LSFH高速铣削加工的加工参数优化研究方面,在充分考虑到各约束条件的模糊性的基础上,将LSFH-刀具配合的力学与动力学特性作为加工参数优化的物理约束条件,建立了高速铣削加工过程切削参数模糊优化模型。优化结果表明,与不考虑约束条件模糊性的常规优化结果及刀具手册的推荐参数相比,高速铣削加工时间分别减少5.95%和8.54%,表面粗糙度分别降低5.42%和6.85%。
在使用LSFH高速铣削加工的加工变形误差补偿研究方面,在前述有限元模型、铣削力模型的建立以及加工参数优化结果的基础上,提出了一种基于铣削力与刀具变形平衡迭代新算法的加工误差补偿方法,实现了高速铣削加工刀具变形误差的离线补偿。加工应用实例表明,加工最大误差由未补偿加工的42μm降低到补偿加工后的9.5μm,使加工误差降低了77.4%。在大型深型腔模具曲面高速铣削加工中,采用本章所提出的离线误差补偿方法,在不牺牲加工效率的情况下能够获得较高的表面加工尺寸精度。
Large-scale and deep cavities injection dies, usually characterized by complex multi-surface, high requirement of machining accuracy, high requirement of surface quality and a long manufacturing cycle, etc., are the key manufacturing equipment to produce the plastic products of the shell of Large-screen color TV sets, computer monitors, car dashboards, interior of vehicle door, etc. At present, the process of manufacturing of such die depends too much on EDM, manual polishing and grinding, personal skills and experience of manufacturer, which make it difficult to guarantee the machining quality, extend the manufacturing cycle greatly and is hard to meet the growing market competition. The matching of lengthened shrink-fit holder (LSFH) and cutter, which has the characteristics of high clamping intensity, high rotary balance, easily close to deep cavity, can meet the diversity requirement of cutter in machining complex multi-surface, etc., become an important means to achieve a high-speed, high-efficiency and high-quality milling of this above die. Nowdays, the advantage of the matching of LSFH-cutter do not give full play due to the lack of in deep study of the registration property, processing parameter optimization and the machining precision control of which when LSFH is used.
This paper focused on the contact characteristics, radial clamping rigidity, dynamics, processing parameter optimization and deformation error compensation of the matching of LSFH and cutter according to the urgent demand of suitable cutter system when high speed milling of large-scale and deep cavity injection. Meanwhile, the analysis model established in the course of study, the effectiveness and practicality of processing parameter optimization and deformation error compensation are verified by experiments.
Firstly, basing on Back-Propagation Neural Network (BPNN), a predictive transient milling force mode of the matching of LSFH-cutter is set up since the transient milling force is the basis of the study of dynamics and deformation error compensation. Before the milling force model is set up, the experiment data are processed properly and the time-parameter is introduced into input vector, then the limitation of the past neural network model only can forecast the average cutting force is overcome. Usually simple gradient descent method to network training easily converges to a local minimum. In order to overcome this shortcoming, the momentum gradient descent learning function and momentum gradient descent BP algorithm training function are used in this forecast model. Test results show that the prediction accuracy is very higher than that of the usual analytical model.
On contact characteristics and radial clamping rigidity of the matching of LSFH and cutter, a parametric finite element model is established and a new method to determine the contact stiffness coefficient of model is given too. The influence of initial basic interference, fit length, fit diameter and centrifugal force caused by high rotation speed on equivalent stress, contact deformation and contact pressure are studied. On this basis, variation coefficient and its calculation method is first introduced to control the reasonable contact state between LSFH and cutter. Subsequently, the influence of interference fit, clamping length and spindle speed on radial clamping rigidity are studied, and at the same time, the critical bending moment under different interference fit is defined theoretically and an effective method to evaluate the static radial clamping rigidity is established too. The results show that: not only the accuracy of analysis results but also the convergence of analysis process can be guaranteed by using the new iterative algorithm presented in this chapter to rapidly determine the stiffness coefficient of the matching of LSFH-cutter; the reasonable contact state should be controlled according to the diameter of cutter; the method to control the reasonable contact given in this paper not can only guarantee the stable and reliable clamping of cutter but also improve the durability of LSFH; in order to have a secure and reliable cutter clamping on condition of high rotation speed, the weaken role of centrifugal force to radial clamping rigidity must be taken into account; the finite element simulation model established in this paper is proved to be correct by the evaluation results of static radial clamping rigidity experiment and the analysis results can provide the reference to the design and selection of the matching of LSFH and cutter.
On dynamics of the matching of LSFH and cutter, the first time, FEA (Finite Element Analysis) technology and EMA (Experiment Modal Analysis) technology are combined to set up the comprehensive finite element model verification and correction process. The influence of overhang length of cutter and spindle speed on dynamic characteristics (include natural frequency and mode shape) are studied. Based on above, transient dynamic of the matching of LSFH and cutter are analyzed in a given processing conditions, and the actual transient displacement response was evaluated. The results show that: the overhang length of cutter affects the natural frequency more significantly; the influence of high rotation speed on dynamic characteristics should be taken into account when the rotation speed exceeds a certain limit; in order to obtain the accurate deformation and force of the matching of LSFH and cutter in an actual high-speed processing condition the influence of transient dynamic must be considered so that the obtained results agree with the actual milling conditions. The results of numerical simulation are verified by experiments. The transient dynamic model can meet the engineering needs and can be used to analyze the actual milling process.
On machining parameters optimization when LSFH is used in high speed milling, a fuzzy optimization model of high speed milling is established on the basis of taking fully into account the fuzziness of all restrictive conditions and takes the mechanics and dynamics of the matching of LSFH and cutter as physical restrictive conditions. The optimization results show that the high speed milling time reduces 5.95%, 8.54% and the surface roughness decrease 5.42, 6.85% compared with the results of the conventional optimization without considering the fuzziness of restrictive conditions and the milling results using the parameters recommended by the cutter manual.
On machining deformation error compensation when LSFH is used in high speed milling, a new compensation method is presented based on an algorithm of iterative balance between milling force and cutter deformation, and the previous finite element model, milling force model and optimization results, then the high speed milling error caused by the deformation of cutter is compensated offline. The milling example shows that the maximum milling error is decreased from 42μm to 9.5μm after compensation, and the milling error reduce about 77.4%. When machining large-scale and deep cavity injection die, high dimensional accuracy of surface finish can be obtained using this compensation method.
本文根据大型深型腔模具对适合其高速铣削加工刀具系统的迫切需要,着重从LSFH-刀具配合的接触特性、径向夹持刚度、动力学特性、加工参数优化以及加工变形误差补偿等方面进行深入研究,并通过试验验证了研究过程中所建分析模型的正确性以及加工参数优化与误差补偿方法的有效性和实用性。
作为动力学特性研究和加工变形误差补偿的前提和基础,首先对基于LSFH-刀具配合的高速铣削加工进行了铣削力建模,建立基于反向传播神经网络(Back-Propagation neural network-BPNN)的瞬态铣削力预测模型。通过对实验数据的适当处理,模型把时间参量引入输入向量,从而克服了以往神经网络切削力预测模型只能预测平均切削力而不能预测瞬态切削力的局限;预测模型采用梯度下降动量学习函数和梯度下降动量BP算法训练函数,避免了单纯的梯度下降法使网络训练易收敛到局部最小值的不足。检验结果表明预测模型具有很好的预测精度,高于通常的铣削力解析模型。
在接触特性及径向夹持刚度研究方面,建立了参数化的有限元模型,并给出了一种合理确定模型中接触刚度系数的新方法。研究了初始基本过盈量、配合长度、配合直径以及高速旋转状态下的离心力对等效应力、接触变形与接触压力等的影响。在此基础上首次引入接触变差系数的概念及其计算方法,给出了实现LSFH-刀具配合的合理接触控制的有效方法。研究了不同配合过盈量、夹持长度及主轴转速对径向夹持刚度的影响,并对不同配合过盈量下的临界弯矩进行了理论界定,建立了静态夹持刚度的有效测量评定方法。研究结果表明:所给出的快速确定LSFH-刀具配合接触刚度系数的迭代算法,既能够保证分析结果的准确,又能够保证分析过程的收敛;应根据不同的刀具配合直径进行合理的接触控制;所给出的合理接触控制方法,既能保证刀具夹持的稳定可靠又能提高LSFH的耐用度;在高转速条件下需充分考虑到离心力对径向夹持刚度的削弱作用,以保证在高转速下实现对刀具安全可靠的夹持;静态径向夹持刚度的评定结果验证了所建有限元仿真模型的正确性,分析结果可为LSFH-刀具配合的设计、选用以及生产实际提供依据。
在动力学特性研究方面,首次将有限元分析(Finite Element Analysis-FEA)技术和试验模态分析(Experiment Modal Analysis-EMA)技术结合起来建立LSFH-刀具配合的有限元模型综合验证与修正流程。分析研究了刀具悬伸出LSFH的长度、主轴转速对LSFH-刀具配合的动力特性包括固有频率和振型的影响。在动力特性分析的基础上对给定加工工况下的LSFH-刀具配合进行了瞬态动力学分析,并对实际的瞬态位移响应进行了评定。研究结果表明:刀具悬伸长度对固有频率的影响较为显著;当转速超过一定时应充分考虑高转速对动力特性的影响;在高速加工工况下,要准确求取加工过程中LSFH-刀具配合的受力与变形,必需考虑到LSFH-刀具配合的瞬态动力学特性的影响,这样才能得出与实际加工工况相符合的正确结论。实际评定结果验证了数值仿真结果的正确性,所建立的瞬态动力学分析模型能够满足工程需要,可用于实际铣削加工过程分析。
在使用LSFH高速铣削加工的加工参数优化研究方面,在充分考虑到各约束条件的模糊性的基础上,将LSFH-刀具配合的力学与动力学特性作为加工参数优化的物理约束条件,建立了高速铣削加工过程切削参数模糊优化模型。优化结果表明,与不考虑约束条件模糊性的常规优化结果及刀具手册的推荐参数相比,高速铣削加工时间分别减少5.95%和8.54%,表面粗糙度分别降低5.42%和6.85%。
在使用LSFH高速铣削加工的加工变形误差补偿研究方面,在前述有限元模型、铣削力模型的建立以及加工参数优化结果的基础上,提出了一种基于铣削力与刀具变形平衡迭代新算法的加工误差补偿方法,实现了高速铣削加工刀具变形误差的离线补偿。加工应用实例表明,加工最大误差由未补偿加工的42μm降低到补偿加工后的9.5μm,使加工误差降低了77.4%。在大型深型腔模具曲面高速铣削加工中,采用本章所提出的离线误差补偿方法,在不牺牲加工效率的情况下能够获得较高的表面加工尺寸精度。
Large-scale and deep cavities injection dies, usually characterized by complex multi-surface, high requirement of machining accuracy, high requirement of surface quality and a long manufacturing cycle, etc., are the key manufacturing equipment to produce the plastic products of the shell of Large-screen color TV sets, computer monitors, car dashboards, interior of vehicle door, etc. At present, the process of manufacturing of such die depends too much on EDM, manual polishing and grinding, personal skills and experience of manufacturer, which make it difficult to guarantee the machining quality, extend the manufacturing cycle greatly and is hard to meet the growing market competition. The matching of lengthened shrink-fit holder (LSFH) and cutter, which has the characteristics of high clamping intensity, high rotary balance, easily close to deep cavity, can meet the diversity requirement of cutter in machining complex multi-surface, etc., become an important means to achieve a high-speed, high-efficiency and high-quality milling of this above die. Nowdays, the advantage of the matching of LSFH-cutter do not give full play due to the lack of in deep study of the registration property, processing parameter optimization and the machining precision control of which when LSFH is used.
This paper focused on the contact characteristics, radial clamping rigidity, dynamics, processing parameter optimization and deformation error compensation of the matching of LSFH and cutter according to the urgent demand of suitable cutter system when high speed milling of large-scale and deep cavity injection. Meanwhile, the analysis model established in the course of study, the effectiveness and practicality of processing parameter optimization and deformation error compensation are verified by experiments.
Firstly, basing on Back-Propagation Neural Network (BPNN), a predictive transient milling force mode of the matching of LSFH-cutter is set up since the transient milling force is the basis of the study of dynamics and deformation error compensation. Before the milling force model is set up, the experiment data are processed properly and the time-parameter is introduced into input vector, then the limitation of the past neural network model only can forecast the average cutting force is overcome. Usually simple gradient descent method to network training easily converges to a local minimum. In order to overcome this shortcoming, the momentum gradient descent learning function and momentum gradient descent BP algorithm training function are used in this forecast model. Test results show that the prediction accuracy is very higher than that of the usual analytical model.
On contact characteristics and radial clamping rigidity of the matching of LSFH and cutter, a parametric finite element model is established and a new method to determine the contact stiffness coefficient of model is given too. The influence of initial basic interference, fit length, fit diameter and centrifugal force caused by high rotation speed on equivalent stress, contact deformation and contact pressure are studied. On this basis, variation coefficient and its calculation method is first introduced to control the reasonable contact state between LSFH and cutter. Subsequently, the influence of interference fit, clamping length and spindle speed on radial clamping rigidity are studied, and at the same time, the critical bending moment under different interference fit is defined theoretically and an effective method to evaluate the static radial clamping rigidity is established too. The results show that: not only the accuracy of analysis results but also the convergence of analysis process can be guaranteed by using the new iterative algorithm presented in this chapter to rapidly determine the stiffness coefficient of the matching of LSFH-cutter; the reasonable contact state should be controlled according to the diameter of cutter; the method to control the reasonable contact given in this paper not can only guarantee the stable and reliable clamping of cutter but also improve the durability of LSFH; in order to have a secure and reliable cutter clamping on condition of high rotation speed, the weaken role of centrifugal force to radial clamping rigidity must be taken into account; the finite element simulation model established in this paper is proved to be correct by the evaluation results of static radial clamping rigidity experiment and the analysis results can provide the reference to the design and selection of the matching of LSFH and cutter.
On dynamics of the matching of LSFH and cutter, the first time, FEA (Finite Element Analysis) technology and EMA (Experiment Modal Analysis) technology are combined to set up the comprehensive finite element model verification and correction process. The influence of overhang length of cutter and spindle speed on dynamic characteristics (include natural frequency and mode shape) are studied. Based on above, transient dynamic of the matching of LSFH and cutter are analyzed in a given processing conditions, and the actual transient displacement response was evaluated. The results show that: the overhang length of cutter affects the natural frequency more significantly; the influence of high rotation speed on dynamic characteristics should be taken into account when the rotation speed exceeds a certain limit; in order to obtain the accurate deformation and force of the matching of LSFH and cutter in an actual high-speed processing condition the influence of transient dynamic must be considered so that the obtained results agree with the actual milling conditions. The results of numerical simulation are verified by experiments. The transient dynamic model can meet the engineering needs and can be used to analyze the actual milling process.
On machining parameters optimization when LSFH is used in high speed milling, a fuzzy optimization model of high speed milling is established on the basis of taking fully into account the fuzziness of all restrictive conditions and takes the mechanics and dynamics of the matching of LSFH and cutter as physical restrictive conditions. The optimization results show that the high speed milling time reduces 5.95%, 8.54% and the surface roughness decrease 5.42, 6.85% compared with the results of the conventional optimization without considering the fuzziness of restrictive conditions and the milling results using the parameters recommended by the cutter manual.
On machining deformation error compensation when LSFH is used in high speed milling, a new compensation method is presented based on an algorithm of iterative balance between milling force and cutter deformation, and the previous finite element model, milling force model and optimization results, then the high speed milling error caused by the deformation of cutter is compensated offline. The milling example shows that the maximum milling error is decreased from 42μm to 9.5μm after compensation, and the milling error reduce about 77.4%. When machining large-scale and deep cavity injection die, high dimensional accuracy of surface finish can be obtained using this compensation method.
引文
[1]http://www.cdmia.com.cn
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