基于机床附件化的旋转超声波加工关键技术研究
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摘要
工程陶瓷广泛应用于航空航天、国防、电子、汽车、生物工程等领域,但陶瓷材料硬度高、脆性大等特点使其加工困难,旋转超声波加工作为一种精密、高效的工程陶瓷加工方法,受到了各国研究人员的广泛关注,实现旋转超声波加工头和负载匹配进给系统的机床附件化,进而促进旋转超声波加工技术的推广应用,是目前必须解决的关键技术问题。
传统的无刷式旋转超声波加工头存在能量传输效率低、传输能力小等问题;现有的机床附件化负载匹配进给系统有软件模式和硬件模式两种,软件模式存在操作和维修复杂、价格昂贵等缺点,硬件模式存在对旋转超声波加工力的变化反应不够灵敏等缺点。
为解决以上问题,本文研究设计一种机床附件化负载匹配进给系统,研究设计一种机床附件化的旋转超声波加工头,研制一种基于电磁感应的无刷式能量传输装置(集流环),并探讨旋转超声波加工过程中刀具磨损的在线监测方法。本文主要研究内容包括以下几方面:
1)研究并设计一种以空气静压导轨气浮工作台为核心的机床附件化负载匹配进给系统。基于气体润滑理论,利用有限元法和试验法对气浮导轨的承载力和承载刚度进行分析和测量,同时完成负载匹配进给系统的力监测和力控制系统。
2)基于电磁感应原理,研究设计一种用于旋转超声波加工头的非接触式能量传输集流环。利用有限元法对比分析四种集流环的工作性能,并进行实验验证。探讨集流环主、副边电路的补偿方法,提出了副边电路负载为换能器时电路的补偿方法,并进行了电路补偿的有限元仿真与实验研究。
3)研究设计一种以柱面感应集流环为核心部件的机床附件化旋转超声波加工头,利用有限元软件对变幅杆进行动力学分析和结构设计。
4)研制旋转超声波钻削SiC陶瓷实验台,利用压电力传感器、振动加速度传感器与声发射传感器在线监测加工过程,通过观测刀具表面形貌判断刀具磨损情况、分析刀具磨损机理,通过信号处理提取表征刀具磨损的信号特征。
5)进行旋转超声波加工负载匹配实验,通过观测工件被加工后的表面质量以及信号分析,验证气浮工作台负载匹配系统对工件的保护作用。
Engineering ceramics are widely used in various areas such as aerospace, defense, electronics, automotive, bioengineering and other fields, However the ceramic materials is difficult to process because of their high hardness, brittleness and other characteristics. As a precision and efficient processing of engineering ceramics, rotary ultrasonic machining has attracted a lot of attention from international researcher. It is a key technical issue that the application of rotary ultrasonic maching is popularised by making the rotary ultrasonic machining head and load matching system accessories.
The energy transfer efficiency and transfer capacity are small in conventional brushless rotary ultrasonic devices. There are software mode and hardware mode in existing accessory load matching system. The normal operation and maintenance are complex and the cost is high in software mode. Responding to the change rotary ultrasonic processing load is not sensitive enough and there are othere shortcomings in hardware mode.
To solve the above problem, a accessory load matching system and a accessory rotary ultrasonic device are researched and designed. A new brushless energy transferring device based on the principle of electromagnetic induction is developed. On-line monitoring tool wear is studied during rotary ultrasonic machining. The studies in this paper include the following aspects:
1) A load matching system of accessoring machine tool is developed, whose core component is an air bearing workbench. The air bearing workbench adops an aerostatic guide. Based on gas lubrication theory, the bearing capacity and stiffness of the aerostatic guide are analyzed and measured by finite element method and experimental method. The monitoring force system and controlling force system of the load matching system are also designed.
2) Based on the principle of electromagnetic induction, a non-contact power transmission collector used in rotary ultrasonic machining is developed. The working performances of four collectors are analyzed by finite element method and are verified by experiments. The circuit compensation method of the primary and secondary circuits is discussed. When the secondary circuit is transducer, the circuit compesnsation is proposed. The circuit compesnsations are analyzed by finite element analysis and are verified by experiments.
3) A rotary ultrasonic device is designed, whose important component is a cylindrical induction power transmission collector. Dynamics of the horn is analyzed by finite element analysis and structure of the horn is designed.
4) A device of rotary ultrasonic drilling of SiC is established for on-line monitoring the process by piezoelectric sensor, vibration sensor and acoustic emission sensor. Tool wear and tool wear mechanism are analyzed by observing the surface morphology. The signal characteristics of tool wear is extracted by processing signals.
5) The load matching system can be employed to protect the workpiece from damage during rotary ultrasonic machining, which is confirmed by observing the machined workpiece surface and analyzing the signals.
传统的无刷式旋转超声波加工头存在能量传输效率低、传输能力小等问题;现有的机床附件化负载匹配进给系统有软件模式和硬件模式两种,软件模式存在操作和维修复杂、价格昂贵等缺点,硬件模式存在对旋转超声波加工力的变化反应不够灵敏等缺点。
为解决以上问题,本文研究设计一种机床附件化负载匹配进给系统,研究设计一种机床附件化的旋转超声波加工头,研制一种基于电磁感应的无刷式能量传输装置(集流环),并探讨旋转超声波加工过程中刀具磨损的在线监测方法。本文主要研究内容包括以下几方面:
1)研究并设计一种以空气静压导轨气浮工作台为核心的机床附件化负载匹配进给系统。基于气体润滑理论,利用有限元法和试验法对气浮导轨的承载力和承载刚度进行分析和测量,同时完成负载匹配进给系统的力监测和力控制系统。
2)基于电磁感应原理,研究设计一种用于旋转超声波加工头的非接触式能量传输集流环。利用有限元法对比分析四种集流环的工作性能,并进行实验验证。探讨集流环主、副边电路的补偿方法,提出了副边电路负载为换能器时电路的补偿方法,并进行了电路补偿的有限元仿真与实验研究。
3)研究设计一种以柱面感应集流环为核心部件的机床附件化旋转超声波加工头,利用有限元软件对变幅杆进行动力学分析和结构设计。
4)研制旋转超声波钻削SiC陶瓷实验台,利用压电力传感器、振动加速度传感器与声发射传感器在线监测加工过程,通过观测刀具表面形貌判断刀具磨损情况、分析刀具磨损机理,通过信号处理提取表征刀具磨损的信号特征。
5)进行旋转超声波加工负载匹配实验,通过观测工件被加工后的表面质量以及信号分析,验证气浮工作台负载匹配系统对工件的保护作用。
Engineering ceramics are widely used in various areas such as aerospace, defense, electronics, automotive, bioengineering and other fields, However the ceramic materials is difficult to process because of their high hardness, brittleness and other characteristics. As a precision and efficient processing of engineering ceramics, rotary ultrasonic machining has attracted a lot of attention from international researcher. It is a key technical issue that the application of rotary ultrasonic maching is popularised by making the rotary ultrasonic machining head and load matching system accessories.
The energy transfer efficiency and transfer capacity are small in conventional brushless rotary ultrasonic devices. There are software mode and hardware mode in existing accessory load matching system. The normal operation and maintenance are complex and the cost is high in software mode. Responding to the change rotary ultrasonic processing load is not sensitive enough and there are othere shortcomings in hardware mode.
To solve the above problem, a accessory load matching system and a accessory rotary ultrasonic device are researched and designed. A new brushless energy transferring device based on the principle of electromagnetic induction is developed. On-line monitoring tool wear is studied during rotary ultrasonic machining. The studies in this paper include the following aspects:
1) A load matching system of accessoring machine tool is developed, whose core component is an air bearing workbench. The air bearing workbench adops an aerostatic guide. Based on gas lubrication theory, the bearing capacity and stiffness of the aerostatic guide are analyzed and measured by finite element method and experimental method. The monitoring force system and controlling force system of the load matching system are also designed.
2) Based on the principle of electromagnetic induction, a non-contact power transmission collector used in rotary ultrasonic machining is developed. The working performances of four collectors are analyzed by finite element method and are verified by experiments. The circuit compensation method of the primary and secondary circuits is discussed. When the secondary circuit is transducer, the circuit compesnsation is proposed. The circuit compesnsations are analyzed by finite element analysis and are verified by experiments.
3) A rotary ultrasonic device is designed, whose important component is a cylindrical induction power transmission collector. Dynamics of the horn is analyzed by finite element analysis and structure of the horn is designed.
4) A device of rotary ultrasonic drilling of SiC is established for on-line monitoring the process by piezoelectric sensor, vibration sensor and acoustic emission sensor. Tool wear and tool wear mechanism are analyzed by observing the surface morphology. The signal characteristics of tool wear is extracted by processing signals.
5) The load matching system can be employed to protect the workpiece from damage during rotary ultrasonic machining, which is confirmed by observing the machined workpiece surface and analyzing the signals.
引文
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