龙门车铣中心液体静压导轨性能的理论分析与实验研究
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摘要
龙门车铣中心集车削和铣削成一体，通过一次装夹即可完成车削与铣削的全部工序，有效地提高了零件的加工精度和效率，在军事、航空、船舶以及其他民用工业领域都得到了广泛的应用。液体静压导轨是龙门车铣中心的关键功能部件之一，其性能的优良程度直接决定车铣中心的加工精度与产品质量。
龙门车铣中心液体静压导轨的结构复杂，各油腔相互耦合，承载力计算困难。本文推导定压、定量及PM控制器供油下油腔承载力的普遍适用超静定力学模型，分析液体静压导轨的静态、动态、振动等性能指标，提出一种基于恒厚度油膜的开式导轨自适应供油方案，采用VC++软件开发油腔承载力计算及性能分析软件，对龙门车铣中心的龙门架及工作台进行现场测试，为龙门车铣中心的性能分析及优化设计提供理论依据。
本文的主要研究内容如下：
(1)考虑多油腔不规则布置的复杂液体静压导轨油腔承载力的超静定耦合问题，将承受外载荷时的油膜厚度表达式作为变形协调方程，详细推导出不同供油方式下多油腔不规则布置的复杂液体静压导轨的承载力普遍适用计算方案，为后续的液体静压导轨性能分析提供基础。
(2)以回转工作台为对象，研究偏心载荷下定压及定量供油方式下各油腔的压力、流量及油膜厚度的耦合关系；对其中一个油腔的供油流量进行调节，研究调节流量对工作台各油腔性能的影响；研究油腔的数目及尺寸对垂直及倾覆载荷作用下导轨的静刚度、承载能力等性能指标的影响，对导轨面内的油腔数目及尺寸进行优化分析，为液体静压导轨的参数优化提供理论依据。
(3)以外载荷为输入、油膜厚度为输出，推导出不同供油方式下闭式、开式液体静压导轨的静态及动态方程，将承载能力、静刚度、功率损失，调整时间、动刚度、相角裕度等分别作为液体静压导轨的静态、动态性能指标，并研究封油边宽度、系统泵压、油液粘度、油膜厚度等设计参数对导轨静态、动态性能的影响，为液体静压导轨的静态、动态性能分析提供理论依据。
(4)根据液体静压导轨的运动学方程及油腔的压力流量方程，假定液体静压导轨的滑板等部件为刚体，得到静压油腔的刚度及阻尼系数，详细推导不同供油方式下闭式、开式液体静压导轨在激振力及激励位移下的振动模型，将固有频率、幅值放大系数等分别作为液体静压导轨的振动性能指标，并研究系统泵压、油液粘度、油膜厚度、油腔压力、导轨质量、载荷频率等设计参数对导轨振动性能的影响，采用VC++开发油腔性能分析软件，为液体静压导轨的振动性能分析提供理论依据。
(5)针对开式液体静压导轨油膜刚度相对较小的情况，提出基于恒厚度油膜的定量泵+比例阀的自适应供油方案，并理论分析定压、定量、PM控制器供油及自适应供油方案的开式液体静压导轨油膜厚度，为提高开式液体静压导轨的油膜刚度提供理论依据。
(6)以现场的一台龙门车铣中心为例，对其回转工作台及龙门架的油腔压力进行现场测试，验证其理论分析的正确性。
Gantry Turning and Milling Center with the integration of turning and milling cancomplete the whole process for just one fixture and improve machining accuracy andefficiency, and then it was used widely in the military, aviation, marine and other fields.The liquid hydrostatic slide, one of the most important key components, makes a fullimpact on the machining precision and quality of Gantry Turning and Milling Center.
Due to complicated structure of liquid hydrostatic slide and coupling action betweenevery oil pocket, it is difficult to calculate the bearing capacity of oil pocket precisely. Sothis paper deduces the universal indeterminate mechanical model of the oil pocket,contrasts the performance of the liquid hydrostatic slide based on three oil-supply methods.According to the weak stiffness of open hydrostatic slide, a novel self-adaption oil-supplymethod is presented. The bearing capacity calculation software and performance analysissoftware are complied with VC++. The gantry frame and worktable used on site areexperimentally validated, and it provides the theoretical foundation for the optimizationand design of Gantry Turning and Milling Center.
The main research contents of this article are as follows:
(1)According to the oil pocket’s complicated arrangement and the intercouplingindeterminate mathematics model, the mathematic expression between the oil filmthickness and the bearing capacity of the oil pocket is established as the deformationcompatibility equation. The universal solution method of the complicated arrangement oilpocket with the different oil supply method is derived in detail. The force calculationprogram is developed using VC++, and it provides a basis for the subsequent performanceanalysis of the liquid hydrostatic slide.
(2)Taking the worktable as the research subject, the influence of the eccentric load onthe oil pocket’s pressure, the rated flow and the oil film thickness with different oil-supplymethod is analyzed. The relationship between the rated flow of the adjusted oil pocket andthe performance indexes of the other oil pockets can be presented in order to keep all oilfilm at a specified thickness. Based on a single slide surface of the liquid hydrostatic slide, the influence of the number and the dimension of the oil pocket on the static stiffness andthe bearing capacity under the vertical load and the overturning torque is analyzed, and thenumber and the dimension of the oil pocket is optimized. And it provides a basis for theparameter optimization of the liquid hydrostatic slide.
(3)Taking the external load and the oil film’s thickness as the input and output of thehydrostatic slide, the static and the dynamic equation with different oil-supply method areestablished. The influence of the design parameter, bearing capacity, static stiffness, powerloss, adjusting time, dynamic stiffness and phase margin, on the static and dynamicperformance index is analyzed separately. And it provides a basis for the static anddynamic performance analysis of the liquid hydrostatic slide.
(4)According to the kinematic equation and the pressure-flow equation of the slide,supposing that the sliding plate is the rigid body, the stiffness and the damping coefficientof the oil pocket are presented. The vibration model of open-type and closed-type liquidhydrostatic slide with different oil-supple method under the exciting force and the excitingdisplacement is established. The influence of the design parameter, as nature frequency,amplitude magnification coefficient, on the vibration performance is analyzed. Theperformance analysis program is developed using VC++, and it provides a basis for thevibration performance analysis of the hydrostatic slide system.
(5)According to the weak oil-film stiffness of open-type hydrostatic slide, a novelself-adaptive oil-supply method based on constant thickness oil-film is presented. The oilfilm thickness of open-type liquid hydrostatic slide separately with constant pressure,constant flow, PM controller and self-adaptive oil-supply methods are contrasted andanalyzed, and it provideds a basis for improving oil-film stiffness of open-type liquidhydrostatic slide.
(6) The field test of the rotary working table and the gantry frame of Gantry Turningand Milling Center used on site are done. It vertifies the correctness of the theoreticalresearch.
龙门车铣中心液体静压导轨的结构复杂，各油腔相互耦合，承载力计算困难。本文推导定压、定量及PM控制器供油下油腔承载力的普遍适用超静定力学模型，分析液体静压导轨的静态、动态、振动等性能指标，提出一种基于恒厚度油膜的开式导轨自适应供油方案，采用VC++软件开发油腔承载力计算及性能分析软件，对龙门车铣中心的龙门架及工作台进行现场测试，为龙门车铣中心的性能分析及优化设计提供理论依据。
本文的主要研究内容如下：
(1)考虑多油腔不规则布置的复杂液体静压导轨油腔承载力的超静定耦合问题，将承受外载荷时的油膜厚度表达式作为变形协调方程，详细推导出不同供油方式下多油腔不规则布置的复杂液体静压导轨的承载力普遍适用计算方案，为后续的液体静压导轨性能分析提供基础。
(2)以回转工作台为对象，研究偏心载荷下定压及定量供油方式下各油腔的压力、流量及油膜厚度的耦合关系；对其中一个油腔的供油流量进行调节，研究调节流量对工作台各油腔性能的影响；研究油腔的数目及尺寸对垂直及倾覆载荷作用下导轨的静刚度、承载能力等性能指标的影响，对导轨面内的油腔数目及尺寸进行优化分析，为液体静压导轨的参数优化提供理论依据。
(3)以外载荷为输入、油膜厚度为输出，推导出不同供油方式下闭式、开式液体静压导轨的静态及动态方程，将承载能力、静刚度、功率损失，调整时间、动刚度、相角裕度等分别作为液体静压导轨的静态、动态性能指标，并研究封油边宽度、系统泵压、油液粘度、油膜厚度等设计参数对导轨静态、动态性能的影响，为液体静压导轨的静态、动态性能分析提供理论依据。
(4)根据液体静压导轨的运动学方程及油腔的压力流量方程，假定液体静压导轨的滑板等部件为刚体，得到静压油腔的刚度及阻尼系数，详细推导不同供油方式下闭式、开式液体静压导轨在激振力及激励位移下的振动模型，将固有频率、幅值放大系数等分别作为液体静压导轨的振动性能指标，并研究系统泵压、油液粘度、油膜厚度、油腔压力、导轨质量、载荷频率等设计参数对导轨振动性能的影响，采用VC++开发油腔性能分析软件，为液体静压导轨的振动性能分析提供理论依据。
(5)针对开式液体静压导轨油膜刚度相对较小的情况，提出基于恒厚度油膜的定量泵+比例阀的自适应供油方案，并理论分析定压、定量、PM控制器供油及自适应供油方案的开式液体静压导轨油膜厚度，为提高开式液体静压导轨的油膜刚度提供理论依据。
(6)以现场的一台龙门车铣中心为例，对其回转工作台及龙门架的油腔压力进行现场测试，验证其理论分析的正确性。
Gantry Turning and Milling Center with the integration of turning and milling cancomplete the whole process for just one fixture and improve machining accuracy andefficiency, and then it was used widely in the military, aviation, marine and other fields.The liquid hydrostatic slide, one of the most important key components, makes a fullimpact on the machining precision and quality of Gantry Turning and Milling Center.
Due to complicated structure of liquid hydrostatic slide and coupling action betweenevery oil pocket, it is difficult to calculate the bearing capacity of oil pocket precisely. Sothis paper deduces the universal indeterminate mechanical model of the oil pocket,contrasts the performance of the liquid hydrostatic slide based on three oil-supply methods.According to the weak stiffness of open hydrostatic slide, a novel self-adaption oil-supplymethod is presented. The bearing capacity calculation software and performance analysissoftware are complied with VC++. The gantry frame and worktable used on site areexperimentally validated, and it provides the theoretical foundation for the optimizationand design of Gantry Turning and Milling Center.
The main research contents of this article are as follows:
(1)According to the oil pocket’s complicated arrangement and the intercouplingindeterminate mathematics model, the mathematic expression between the oil filmthickness and the bearing capacity of the oil pocket is established as the deformationcompatibility equation. The universal solution method of the complicated arrangement oilpocket with the different oil supply method is derived in detail. The force calculationprogram is developed using VC++, and it provides a basis for the subsequent performanceanalysis of the liquid hydrostatic slide.
(2)Taking the worktable as the research subject, the influence of the eccentric load onthe oil pocket’s pressure, the rated flow and the oil film thickness with different oil-supplymethod is analyzed. The relationship between the rated flow of the adjusted oil pocket andthe performance indexes of the other oil pockets can be presented in order to keep all oilfilm at a specified thickness. Based on a single slide surface of the liquid hydrostatic slide, the influence of the number and the dimension of the oil pocket on the static stiffness andthe bearing capacity under the vertical load and the overturning torque is analyzed, and thenumber and the dimension of the oil pocket is optimized. And it provides a basis for theparameter optimization of the liquid hydrostatic slide.
(3)Taking the external load and the oil film’s thickness as the input and output of thehydrostatic slide, the static and the dynamic equation with different oil-supply method areestablished. The influence of the design parameter, bearing capacity, static stiffness, powerloss, adjusting time, dynamic stiffness and phase margin, on the static and dynamicperformance index is analyzed separately. And it provides a basis for the static anddynamic performance analysis of the liquid hydrostatic slide.
(4)According to the kinematic equation and the pressure-flow equation of the slide,supposing that the sliding plate is the rigid body, the stiffness and the damping coefficientof the oil pocket are presented. The vibration model of open-type and closed-type liquidhydrostatic slide with different oil-supple method under the exciting force and the excitingdisplacement is established. The influence of the design parameter, as nature frequency,amplitude magnification coefficient, on the vibration performance is analyzed. Theperformance analysis program is developed using VC++, and it provides a basis for thevibration performance analysis of the hydrostatic slide system.
(5)According to the weak oil-film stiffness of open-type hydrostatic slide, a novelself-adaptive oil-supply method based on constant thickness oil-film is presented. The oilfilm thickness of open-type liquid hydrostatic slide separately with constant pressure,constant flow, PM controller and self-adaptive oil-supply methods are contrasted andanalyzed, and it provideds a basis for improving oil-film stiffness of open-type liquidhydrostatic slide.
(6) The field test of the rotary working table and the gantry frame of Gantry Turningand Milling Center used on site are done. It vertifies the correctness of the theoreticalresearch.
引文
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