大型丝杠的旋风铣削加工工艺优化研究
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摘要
硬铣削加工(即旋风铣削加工)是二十世纪中后期产生的一种新型切削加工方式,因其高效、优质、低耗、清洁等优势成为切削加工的主流方式,被广泛地运用到螺纹及丝杠的切削加工中。本文以提高大型丝杠的旋风铣削加工精度为目的,通过理论建模与有限元仿真的方法研究大型丝杠的旋风铣削加工过程,并对其加工工艺进行优化。
针对大型丝杠刚度低的问题,建立了多支撑下的大型丝杠的旋转动力学模型,且在建模的过程中考虑丝杠旋转速度,丝杠自重对大型丝杠旋转动力学研究的影响。运用有限元仿真技术与MATLAB中的遗传算法工具箱对支撑布局进行优化。
对大型丝杠的旋风铣削加工工艺优化的方法进行了研究。由于粒子群算法收敛速度快、核心程序简单、涉及学科知识少等优点,重点研究了粒子群算法并编写了粒子群算法程序。针对粒子群算法存在的缺陷,提出了基于随机方向法的粒子群算法(RDM-PSO)来弥补该缺陷。通过测试函数分析及与其它文献对比,对基于随机方向法的粒子群算法的算法性能进行了研究,并将其运用到大型丝杠的支撑布局再优化中。
建立了大型丝杠旋风铣削加工的瞬时切削厚度模型,刀-屑接触长度模型,并基于高速切削加工理论,建立了大型丝杠旋风铣削加工的切削力理论模型,同时通过有限元切削仿真,得到不同旋风铣削加工参数,不同刀具结构下的旋风铣削力、表层残余应力、切屑形态等。
建立大型丝杠在沿轴向移动的断续旋风铣削力作用下的动力学模型,通过使用wilson-θ法求解此模型得到不同旋风铣削工况下的大型丝杠的动力学响应,同时在ABAQUS中,对大型丝杠旋风铣削加工模型进行模态动态分析得到大型丝杠的动力学响应,且在MATLAB数值模拟与有限元模态动态分析的过程中,考虑大型丝杠的旋转速度、自重,铣刀盘的轴向进给速率,断续旋风铣削力,夹紧力对大型丝杠动力学响应的影响。
最后,将大型丝杠在沿轴向移动断续旋风铣削力作用下的动力学响应值作为目标函数,使用基于随机方向法的粒子群算法与MATLAB遗传算法工具箱对旋风铣削加工参数进行优化。
Hard whirling is a new manufacturing method which is discovered by the middle of 20 century. It is famous for its high quality, high efficiency, low-consuming, clearness, and has been intensively used in screw and ball screw manufacturing. In this article, we aim at improve the machining accuracy of large ball screw. Meanwhile, we use theoretical modeling and finite element analysis to optimize the manufacturing process.
Firstly, in order to increase the rigidity of large ball screw, we build the dynamic equation of large ball screw under supports, taking consider of rotating speed and gravity of large ball screw, and use Genetic Algorithm toolbox in MATLAB and Finite element analysis to optimize the layout of supports.
Secondly, do research about the method to optimizing manufacturing process which is called optimization algorithm. Because Particle Swarm Optimization algorithm has fast convergence efficiency, simple procedure, little subject involved and so on, so in this article we are mainly focus on it, what's more, we improve the performance of Particle Swarm Optimization algorithm through adding Random Direction Method into it, and we use RDM-PSO to optimize the layout of supports again.
Thirdly, modeling the minimum chip thickness, the instantaneous chip thickness and tool-work contact length, and theoretically build the whirling force model according to high speed metal cutting theory, meanwhile study whirling force, surface residual force, chip shape under different whirling condition and the structure of cutter through metal cutting simulation in ABAQUS.
Fourthly, build the dynamic equation of rotating large ball screw under axially moving interrupted whirling force, solving this equation and doing dynamic modal analysis of large ball screw under whirling in ABAQUS to get ball screw's deflection, taking consider of the rotating speed and gravity of ball screw, axially moving interrupted whirling force and clamping force.
Finally, we consider the deflection of ball screw under axially moving interrupted whirling force as objection function, and use RDM-PSO and GATO to optimize the whirling parameter.
针对大型丝杠刚度低的问题,建立了多支撑下的大型丝杠的旋转动力学模型,且在建模的过程中考虑丝杠旋转速度,丝杠自重对大型丝杠旋转动力学研究的影响。运用有限元仿真技术与MATLAB中的遗传算法工具箱对支撑布局进行优化。
对大型丝杠的旋风铣削加工工艺优化的方法进行了研究。由于粒子群算法收敛速度快、核心程序简单、涉及学科知识少等优点,重点研究了粒子群算法并编写了粒子群算法程序。针对粒子群算法存在的缺陷,提出了基于随机方向法的粒子群算法(RDM-PSO)来弥补该缺陷。通过测试函数分析及与其它文献对比,对基于随机方向法的粒子群算法的算法性能进行了研究,并将其运用到大型丝杠的支撑布局再优化中。
建立了大型丝杠旋风铣削加工的瞬时切削厚度模型,刀-屑接触长度模型,并基于高速切削加工理论,建立了大型丝杠旋风铣削加工的切削力理论模型,同时通过有限元切削仿真,得到不同旋风铣削加工参数,不同刀具结构下的旋风铣削力、表层残余应力、切屑形态等。
建立大型丝杠在沿轴向移动的断续旋风铣削力作用下的动力学模型,通过使用wilson-θ法求解此模型得到不同旋风铣削工况下的大型丝杠的动力学响应,同时在ABAQUS中,对大型丝杠旋风铣削加工模型进行模态动态分析得到大型丝杠的动力学响应,且在MATLAB数值模拟与有限元模态动态分析的过程中,考虑大型丝杠的旋转速度、自重,铣刀盘的轴向进给速率,断续旋风铣削力,夹紧力对大型丝杠动力学响应的影响。
最后,将大型丝杠在沿轴向移动断续旋风铣削力作用下的动力学响应值作为目标函数,使用基于随机方向法的粒子群算法与MATLAB遗传算法工具箱对旋风铣削加工参数进行优化。
Hard whirling is a new manufacturing method which is discovered by the middle of 20 century. It is famous for its high quality, high efficiency, low-consuming, clearness, and has been intensively used in screw and ball screw manufacturing. In this article, we aim at improve the machining accuracy of large ball screw. Meanwhile, we use theoretical modeling and finite element analysis to optimize the manufacturing process.
Firstly, in order to increase the rigidity of large ball screw, we build the dynamic equation of large ball screw under supports, taking consider of rotating speed and gravity of large ball screw, and use Genetic Algorithm toolbox in MATLAB and Finite element analysis to optimize the layout of supports.
Secondly, do research about the method to optimizing manufacturing process which is called optimization algorithm. Because Particle Swarm Optimization algorithm has fast convergence efficiency, simple procedure, little subject involved and so on, so in this article we are mainly focus on it, what's more, we improve the performance of Particle Swarm Optimization algorithm through adding Random Direction Method into it, and we use RDM-PSO to optimize the layout of supports again.
Thirdly, modeling the minimum chip thickness, the instantaneous chip thickness and tool-work contact length, and theoretically build the whirling force model according to high speed metal cutting theory, meanwhile study whirling force, surface residual force, chip shape under different whirling condition and the structure of cutter through metal cutting simulation in ABAQUS.
Fourthly, build the dynamic equation of rotating large ball screw under axially moving interrupted whirling force, solving this equation and doing dynamic modal analysis of large ball screw under whirling in ABAQUS to get ball screw's deflection, taking consider of the rotating speed and gravity of ball screw, axially moving interrupted whirling force and clamping force.
Finally, we consider the deflection of ball screw under axially moving interrupted whirling force as objection function, and use RDM-PSO and GATO to optimize the whirling parameter.
引文
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[2]T. N. SHIAU, E. C. CHEN, K. H. HUANG, W. C. HSU. Dynamic Response of a spinning Timoshenko Beam with General Boundary Conditions under a Moving Skew Force Using Global Assumed Mode Method, JSME International Journal, Series C, Vol.49, No.2, (2006):401-410
[3]Huajiang Ouyang, Minjie Wang. Dynamics of a Rotating Shaft Subject to a Three-Directional Moving Load [J]. Journal of Vibration and Acoustics, Vol.129, JUNE (2007):386-389.
[4]Y. M. Huang, M. L. Yang, Dynamic analysis of a rotating beam subjected to repeating axial and transverse forces for simulating a lathing process[J], International Journal of Mechanical Sciences 51 (2009):256-268
[5]T.N. Shiau, K.H. Huang, F.C. Wang, K.H. Chen, C.P. Kuo. Dynamic response of a rotating ball screw subject to a moving regenerative force in grinding, Applied Mathematical Modeling 34 (2010):1721-1731
[6]T.N. Shiau et al, Dynamic response of a rotating multi-span shaft with general boundary conditions subjected to a moving load [J]. Journal of Sound and Vibration 323 (2009):1045-1060
[7]A. V. Phan, G. Cloutier, J. Mayer, A finite element model with closed-form solutions to work Piece deflections in turning. International Journal of Production research,1999, 37:4039-4051.
[8]J. Mayer, A. V. Phan, G. Cloutier. Prediction of diameter errors in bar turning:A computationally effective model. Applied Mathematical Modelling.2000,24:943-956
[9]A. V. Phan, L. Baron, J. Mayer. Finite element and experimental studies of diameter errors in cantilever bar turning. Applied Mathematical Modelling.2003,27:221-232
[10]L. Carrino, G. Giorleo, W. Polini, et al. Dimensional Errors in Longitudinal Turning Based on the Unified Generalized Mechanics of Cutting Approach. International Journal of Machine Tools & Manufacture.2002,42:150-152.
[11]R. Azouzi, M. Guillot. On-line Prediction of Surface Finish and Dimensional Deviation in Turning Using Neural Network Based Sensor Fusion. International Journal of Machine Tools & Manufacture.1997,37(9):1201-1217
[12]K.A. Risbood, U.S. Dixit, A.D. Sahasrabudhe. Prediction of Surface Roughness and Dimensional Deviation by Measuring Cutting Forces and Vibrations in Turning Process. Journal of Materials Processing Technology.2003,132:203-214
[13]C.K. Chen, Y.M. Tsao. A stability analysis of turning a tailstock supported flexible work-piece, International Journal of Machine Tools & Manufacture 46 (2006) 18-25
[14]Y. M. HUANG, K. K. CHANG. Stability analysis of a rotating beam under a moving motion-dependent force, Journal of Sound and Vibration (1997)202(3),427-437
[15]郭建亮.细长轴类工件车削加工的研究.哈尔滨工业大学博世论文,2006年5月
[16]范胜波.虚拟数控车削加工质量预测系统的研究.天津大学博士学位论文,2005：38-45
[17]吴昊,杨建国,张宏韬,王秀山.精密车削中心热误差鲁棒建模与实时补偿.上海交通大学学报,第42卷第7期,2008年7月
[18]崔伯第.细长轴车削参数优化及尺寸误差监测系统研究.哈尔滨工业大学博世论文,2008年8月
[19]武文革,庞思勤,常兴.可逆向车削细长轴加工误差的力学分析.北京理工大学学报,第24卷,第2期,(2004)：109-112
[20]谭立新.五轴联动旋风铣削机床切削运动仿真及误差补偿研究.中南大学硕士学位论文,(2007)：4-5
[21]李小忠.高速切削有限元仿真及加工参数优化的研究.南京理工大学硕士学位论文,2007年7月
[22]张贇,董长双.基于MAT LAB粒子群算法的切削用量优化.机械工程及自动化,第2期(总第165期),2011：119-121
[23]SHI Y H, Eberhart R C.A modified particle swarm optimizer [A]. IEEE International Conference on Evolutionary Computation[C]. Anchorage, Alaska, May4-9,1998
[24]朱小六,熊伟丽,徐保国.基于动态惯性因子的PSO算法的研究[J].计算机仿真,2007,24(5)：154-157
[25]雷开友.粒子群算法及其应用研究[D].西南大学博士学位论文,2006.06
[26]沈艳,郭兵,古天祥.粒子群优化算法及其与遗传算法的比较.电子科技大学学报,第34卷,第5期,2005：696-699
[27]Eberhart R.C. Shi Yuhui. Particle Swarm Optimization:Developments, Applications and Resources 2001
[28]CLERC M. The swarm and the queen:towards a deterministic and adaptive particle swarm optimization[C]//Proc of the ICEC. [S.I.]; IEEE Press,1999:1951-1957
[29]Ting-Yu Chen, Tzu-Ming Chi, On the improvements of the particle swarm optimization algorithm [J], Advances in Engineering Software 41 (2010) 229-239
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