基于刚性散体的抛光头柔度控制与抛光技术研究
摘要
随着科学技术的进步和制造业的不断发展,模具的应用日益广泛,特别是在航空航天、汽车制造业等高新技术领域。模具的制造设计水平已经成为衡量一个国家工业发展水平的重要标志。但是,国内外对模具表面的精加工多以手工抛光为主,去除效率低,加工周期长,质量也不稳定。为解决这些问题,本文提出了一种新的柔性抛光技术——基于刚性散体的柔度连续可调抛光技术。基于刚性散体的柔度连续可调抛光技术是柔性抛光技术(如气囊抛光和磁流变液抛光)的延续,是一种可以得到高精度和高效率的先进抛光技术,是一种具有较强创新性、实用性的模具自由曲面抛光技术,值得进行积极探索和推广应用。该抛光技术用于金属模具的抛光,可以精确地控制被抛光工件的型面,材料去除效率高,对于模具的粗抛很有意义。本文研究的内容主要包括以下几个部分:
1、在对国内外模具抛光技术和应用状况进行分析后,结合本项目抛光技术的特点,基于散体力学、电磁学原理及偶极子的物理模型,建立以理想铁球为研究对象的模型,并通过剪切试验对这一理想铁球模型进行修正。
2、基于修正的力学模型,开发了一种应用于模具自由曲面抛光的机器人抛光系统。该系统利用MOTOMAN-HP20型机器人作为抛光工具的载体,通过对该型机器人的控制实现抛光轨迹的自动规划,从而构成一套完整的自动化抛光系统。与传统的刚性抛光方式相比,由于该系统采用柔性技术,抛光头刚度可随磁场强度实时调整,且其不同的抛光轨迹均可通过机器人的控制加以实现,因此该系统能够实现不同型面的柔性抛光。经试验验证,该抛光技术切实可行,去除效率高。
3、为本抛光技术在模具行业内的推广应用,在分析机床功能和运动要求的基础上,设计了基于刚性散体的柔性抛光原型样机,并对其中的关键技术进行分析和研究。
本文对磁控散体抛光的原理和应用进行了初步探讨,为今后进一步的研究打下了良好的基础。
Along with the progress on science and technology and the continuous development of manufacturing industry, mold is widely used day by day particularly in high-tech fields such as aerospace, automotive manufacturing etc. Mold manufacturing and design level has become an important symbol to measure a country's industrial development level. However, finishing machining method on the surface of mold is mainly manual polishing nowadays, which has a low removing efficiency, long processing cycle and unstable quality. In order to solve these problems, a new flexible polishing technology that is adjustable flexibility polishing technology based on rigid granular was presented in this dissertation. Adjustable flexibility polishing technology based on rigid granular is a continuation of flexible polishing technology such as bonnet tool polishing and magnetorheological fluid polishing, which is a advanced polishing technique with high precision and high efficiency. It is also a kind of mold free-surface polishing technology with strong innovation and practicality, which worth to explore actively and expand. While this polishing technology were used in polishing metal mold, the workpiece surface can be precisely controlled by polishing with high material removal efficiency, which has a significant meaning in rough polishing mold. The contents of the study include the following parts:
(1) A model regarded ideal iron sphere as study object was established after the analysis on mold polishing technology and application situation, with the combination of characteristics of polishing technology, based on granular mechanics, electromagnetic principle and physical model of dipole. Then the model was modified by shear test.
(2) A robot polishing system was developed applied in polishing free-form surface of mold based on modified mechanical model. The system uses Motorman MOTOMAN-HP20 as a carrier of polishing tools. An automated polishing system was established through controlling the robot to achieve the automatic polishing trajectory planning. Compared with traditional polishing method, this system can realize flexible polishing on different types of surface. Because this system uses flexible technology, the polishing head stiffness can be adjusted along with the magnetic field strength in real-time, and different polishing trajectories can be realized by controlling the robot. The experimental results show that the polishing technology is practical, with high removal efficiency.
(3) A flexible polishing prototype based on rigid granular was designed after the analysis of machine function and movement requirements in order to spread the polishing technology application on mold industry. Some key technology were also analyzed and researched.
In this dissertation, the polishing principle and application of magnetic granular was also discussed which provide a good foundation for further research.
1、在对国内外模具抛光技术和应用状况进行分析后,结合本项目抛光技术的特点,基于散体力学、电磁学原理及偶极子的物理模型,建立以理想铁球为研究对象的模型,并通过剪切试验对这一理想铁球模型进行修正。
2、基于修正的力学模型,开发了一种应用于模具自由曲面抛光的机器人抛光系统。该系统利用MOTOMAN-HP20型机器人作为抛光工具的载体,通过对该型机器人的控制实现抛光轨迹的自动规划,从而构成一套完整的自动化抛光系统。与传统的刚性抛光方式相比,由于该系统采用柔性技术,抛光头刚度可随磁场强度实时调整,且其不同的抛光轨迹均可通过机器人的控制加以实现,因此该系统能够实现不同型面的柔性抛光。经试验验证,该抛光技术切实可行,去除效率高。
3、为本抛光技术在模具行业内的推广应用,在分析机床功能和运动要求的基础上,设计了基于刚性散体的柔性抛光原型样机,并对其中的关键技术进行分析和研究。
本文对磁控散体抛光的原理和应用进行了初步探讨,为今后进一步的研究打下了良好的基础。
Along with the progress on science and technology and the continuous development of manufacturing industry, mold is widely used day by day particularly in high-tech fields such as aerospace, automotive manufacturing etc. Mold manufacturing and design level has become an important symbol to measure a country's industrial development level. However, finishing machining method on the surface of mold is mainly manual polishing nowadays, which has a low removing efficiency, long processing cycle and unstable quality. In order to solve these problems, a new flexible polishing technology that is adjustable flexibility polishing technology based on rigid granular was presented in this dissertation. Adjustable flexibility polishing technology based on rigid granular is a continuation of flexible polishing technology such as bonnet tool polishing and magnetorheological fluid polishing, which is a advanced polishing technique with high precision and high efficiency. It is also a kind of mold free-surface polishing technology with strong innovation and practicality, which worth to explore actively and expand. While this polishing technology were used in polishing metal mold, the workpiece surface can be precisely controlled by polishing with high material removal efficiency, which has a significant meaning in rough polishing mold. The contents of the study include the following parts:
(1) A model regarded ideal iron sphere as study object was established after the analysis on mold polishing technology and application situation, with the combination of characteristics of polishing technology, based on granular mechanics, electromagnetic principle and physical model of dipole. Then the model was modified by shear test.
(2) A robot polishing system was developed applied in polishing free-form surface of mold based on modified mechanical model. The system uses Motorman MOTOMAN-HP20 as a carrier of polishing tools. An automated polishing system was established through controlling the robot to achieve the automatic polishing trajectory planning. Compared with traditional polishing method, this system can realize flexible polishing on different types of surface. Because this system uses flexible technology, the polishing head stiffness can be adjusted along with the magnetic field strength in real-time, and different polishing trajectories can be realized by controlling the robot. The experimental results show that the polishing technology is practical, with high removal efficiency.
(3) A flexible polishing prototype based on rigid granular was designed after the analysis of machine function and movement requirements in order to spread the polishing technology application on mold industry. Some key technology were also analyzed and researched.
In this dissertation, the polishing principle and application of magnetic granular was also discussed which provide a good foundation for further research.
引文
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