五轴联动螺旋锥齿轮磨齿机各轴几何误差测量与补偿
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摘要
数控机床几何位置精度是机床评定的重要指标,直接影响到机床的加工精度。如何提高数控机床的几何位置精度成为目前研究的关键问题。对于高精密数控机床,机床几何精度的提高至关重要,但是机床部件加工误差及机床装配误差等误差给机床几何位置精度提高带来了困难。采用数控系统误差补偿的方法可以使数控机床获得较高的几何精度,且具有成本低的优点。
本文结合螺旋锥齿轮加工原理及齐次坐标变换方法,建立螺旋锥齿轮数控磨齿机YK2050几何误差模型。并分析五轴定位误差对齿轮齿面精度的影响,为螺旋锥齿轮加工精度提高和机床误差建模提供参考。机床几何误差测量直接关系到机床几何误差数学模型的准确性,且影响到机床误差补偿的效果。本文采用激光多普勒位移测量仪测量螺旋锥齿轮数控磨齿机YK2050直线轴及回转轴共16项几何误差,并采用ISO 230-2(1997)标准进行机床几何误差评定。为机床出厂误差评定提供了参考。
本文对软件误差补偿法及SINUMERIK 840D系统误差补偿方法进行了研究。在数控磨齿机YK2050上进行了误差补偿实验,分别对直线轴和回转轴定位误差进行补偿。实验结果表明,数控系统误差补偿效果较好,机床几何精度得到了明显提高。采用CMM齿轮检测仪测量磨齿机误差补偿前后所加工齿轮齿面误差。通过比较齿面误差验证机床几何精度的提高可提高机床加工精度。实验结果表明,螺旋锥齿轮数控机床的几何精度提高,其齿轮加工精度也提高。
Geometric positioning accuracy which is an important indicator of Computer Numerically Controlled(CNC) machine assess directly affects machining accuracy. How to improve geometric positioning accuracy of CNC machine becomes an significant issue of present research. Improvement of geometric positioning accuracy is very crucial for high precision machine tool. But processing error and assembly error of machine tool hinder the improvement of geometric positioning accuracy. CNC machine can get high geometric positioning accuracy by adopting the method of error compensation of numerical control system.
Geometric positioning error model of CNC grinding machine of spiral bevel gear(YK2050) is founded on the basis of spiral bevel gear's machining theory and Descart cordinate transformation. The effect of positioning error of the five axes on tooth precision is studied that is referrence for the improvement of machining accuracy of spiral bevel gear and modeling of geometric positioning error of machine tool. Measurement of geometric positioning error of machine tool directly affects the modeling and error compensation of the machine tool. Sixteen positioning errors of linear and rotational axes of spiral bevel gear(YK2050) are measured by using Laser Doppler Displacement Measurement Device. And the geometric positioning errors are assessed by using ISO 230-2 (1997),which is referrence for error assessment of newly produced produced machine tool.
Software error compensation and error compensation of SINUMERIK 840D system is studied. Experiments about compensation of positioning error of linear and rotational axes is carryed out on CNC grinding machine of spiral bevel gear(YK2050). The result of experiments indicates that the effect of CNC error compensation is great. And geometric positioning accuracy of the machine tool is improved greatly. Tooth deviation of the grinding machine both before and after the error compensation are measured by using CMM gear measuring device. That improvement of geometric positioning accuracy of machine tool can improve its processing precision is testified by comparation of tooth deviation. The result of experiments indicates that improvement of geometric positioning accuracy of CNC machine tool of Spiral Bevel Gear can improve machining precision of gears.
本文结合螺旋锥齿轮加工原理及齐次坐标变换方法,建立螺旋锥齿轮数控磨齿机YK2050几何误差模型。并分析五轴定位误差对齿轮齿面精度的影响,为螺旋锥齿轮加工精度提高和机床误差建模提供参考。机床几何误差测量直接关系到机床几何误差数学模型的准确性,且影响到机床误差补偿的效果。本文采用激光多普勒位移测量仪测量螺旋锥齿轮数控磨齿机YK2050直线轴及回转轴共16项几何误差,并采用ISO 230-2(1997)标准进行机床几何误差评定。为机床出厂误差评定提供了参考。
本文对软件误差补偿法及SINUMERIK 840D系统误差补偿方法进行了研究。在数控磨齿机YK2050上进行了误差补偿实验,分别对直线轴和回转轴定位误差进行补偿。实验结果表明,数控系统误差补偿效果较好,机床几何精度得到了明显提高。采用CMM齿轮检测仪测量磨齿机误差补偿前后所加工齿轮齿面误差。通过比较齿面误差验证机床几何精度的提高可提高机床加工精度。实验结果表明,螺旋锥齿轮数控机床的几何精度提高,其齿轮加工精度也提高。
Geometric positioning accuracy which is an important indicator of Computer Numerically Controlled(CNC) machine assess directly affects machining accuracy. How to improve geometric positioning accuracy of CNC machine becomes an significant issue of present research. Improvement of geometric positioning accuracy is very crucial for high precision machine tool. But processing error and assembly error of machine tool hinder the improvement of geometric positioning accuracy. CNC machine can get high geometric positioning accuracy by adopting the method of error compensation of numerical control system.
Geometric positioning error model of CNC grinding machine of spiral bevel gear(YK2050) is founded on the basis of spiral bevel gear's machining theory and Descart cordinate transformation. The effect of positioning error of the five axes on tooth precision is studied that is referrence for the improvement of machining accuracy of spiral bevel gear and modeling of geometric positioning error of machine tool. Measurement of geometric positioning error of machine tool directly affects the modeling and error compensation of the machine tool. Sixteen positioning errors of linear and rotational axes of spiral bevel gear(YK2050) are measured by using Laser Doppler Displacement Measurement Device. And the geometric positioning errors are assessed by using ISO 230-2 (1997),which is referrence for error assessment of newly produced produced machine tool.
Software error compensation and error compensation of SINUMERIK 840D system is studied. Experiments about compensation of positioning error of linear and rotational axes is carryed out on CNC grinding machine of spiral bevel gear(YK2050). The result of experiments indicates that the effect of CNC error compensation is great. And geometric positioning accuracy of the machine tool is improved greatly. Tooth deviation of the grinding machine both before and after the error compensation are measured by using CMM gear measuring device. That improvement of geometric positioning accuracy of machine tool can improve its processing precision is testified by comparation of tooth deviation. The result of experiments indicates that improvement of geometric positioning accuracy of CNC machine tool of Spiral Bevel Gear can improve machining precision of gears.
引文
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[2]LEE W, LI J, CHEUNG C. Development of a virtual training workshop in ultra-precision machining. International Journal of Engineering Education,2002,18(5):584-96
[3]LEE W, GAO D, CHEUNG C, et al. Computer-integrated optics design and tool path generation in virtual machining of aspheric surfaces. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture,2003,217(9):85-94
[4]LEE W, GAO D, CHEUNG C, et al. An NC tool path translator for virtual machining of precision optical products. Journal of Materials Processing Technology,2003,140(1-3):211-226
[5]李建广,李荣彬.提高虚拟车削仿真质量的工件建模方法.计算机集成制造系统,2002,8(003)：233-238
[6]PORTMAN V, SHUSTER V. Layout errors of machine tools. International Journal of Machine Tools and Manufacture,1997,37(10):1485-97
[7]LI S, ZHANG Y, ZHANG G. A study of pre-compensation for thermal errors of NC machine tools. International Journal of Machine Tools and Manufacture,1997,37(12):5-9
[8]CHEUNG C, LEE W. Modelling and simulation of surface topography in ultra-precision diamond turning. Proceedings of the Institution of Mechanical Engineers, Part B:Journal of Engineering Manufacture, 2000,214(6):63-80
[9]李荣彬,张志辉,李建广.超精密加工的三维表面形貌预测.中国机械工程,2000,11(008)：45-80
[10]KIM K, KIM M. Volumetric accuracy analysis based on generalized geometric error model in multi-axis machine tools. Mechanism and Machine Theory,1991,26(2):7-19
[11]SOONS J, THEUWS F, SCHELLEKENS P. Modeling the errors of multi-axis machines:a general methodology. Precision Engineering,1992,14(1): 5-19
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[13]李圣怡,戴一帆,等.精密和超精密机床精度建模技术.长沙：国防科技大学出版社,2007.20-50
[14]李小力.数控机床综合几何误差的建模及补偿研究：[博士学位论文].武汉：华中科技大学,2006
[15]李彦征,王树新.考虑运动误差的数控插齿机插齿啮合分析.机械传动, 2003,27(006)：1-4
[16]李彦征,王树新.数控插齿机的误差建模及仿真分析.制造业自动化,2003,1(003)：20-25
[17]丁文政,周明虎,黄筱调,等.面向再制造的多轴机床精度设计研究.应用基础与工程科学学报,2007,15(004)：59-68
[18]辜志刚,谌永祥.三坐标数控机床误差补偿技术.兵工自动化,2004,23(002)：19-20
[19]孙长库,叶声华.激光测量技术.天津：天津大学出版社,2001.30-160
[20]金国藩,李景镇.激光测量学.北京：科学出版社,1998.30-100
[21]茅振华,孙鲁涌.数控机床精度的激光干涉法测试与补偿.机电工程,1999,16(004)：48-9
[22]杨国光.近代光学测试技术.北京：机械工业出版社,1986.30-100
[23]羡一民,王科峰.激光干涉仪技术及发展.工具技术,2003,37(011)：68-74
[24]殷纯永.现代干涉测量技术.天津：天津大学出版社.1999.40-110
[25]杜振辉,蒋诚志,桂垣等.激光干涉仪测量长度.河北建筑工程学院学报,2003,21(002)：3-7
[26]胡绍楼.激光干涉测速技术.北京： 国防工业出版社,2001.30-100
[27]邾继贵,叶声华.衍射法细丝直径的精密测量.光电工程,1996,23(003)：59-63
[28]刘慧玲.数控螺旋锥齿轮机床空间位置精度检测与补偿研究：[硕士学位论文].长沙：中南大学,2006
[29]金永君.光多普勒效应及应用.现代物理知识,2003,15(004)：14-25
[30]王仕康,沈熊,周作元.激光多普勒技术.北京：清华大学出版社,1985.50-110
[31]WANG C. Laser doppler displacement measuring system and apparatus. Google Patents.1987
[32]李小力,周云飞.数控机床位置误差建模与补偿.机械设计与制造工程,1999,28(002)：48-50
[33]FANG C, FAN K. Development of multi-function error calibration system for NC machine tools, International Journal of Machine Tools and Manufacture,1990,35(4):40-45
[34]CHEN J, YUAN J, NI J, et al. Real-time compensation for time-variant volumetric errors on a matching center. J Eng Ind Trans ASME,1993, 115(4):72-90
[35]吴小川.激光测量技术在数控机床定位精度检验中的应用.计量与测试技术,2000,27(004)：10-15
[36]WANG C. Laser vector measurement technique for the determination and compensation of volumetric positioning errors. Part Ⅰ:Basic theory. Review of scientific instruments,2000,7(39):33-40
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