大型数控滚齿机静压导轨力学性能研究
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摘要
工作台静压导轨是大型数控滚齿机的重要部件,它的力学性能优劣直接影响整个机床的加工质量、寿命和运行效率。随着现代工业的发展,数控机床越来越趋向于对速度和承载的极端化要求,对于静压导轨的力学性能提出了越来越高的要求。为了提高工作台承载能力,延长工作台使用寿命,提高机床的加工精度,有必要在理论分析、仿真计算和科学试验的基础上对液体静压导轨静态力学性能进行深入研究。
本文主要包括以下几部分内容:
①首先综合论述了液体静压导轨的特点及研究意义,然后分析了国内外静压技术发展应用的历史及现状,最后介绍了本文的研究目的、内容和主要工作。
②针对现有供油系统油膜厚度调节精度不高,实时补偿调节能力不强的问题,对其进行改进,提出一种工作压力高、能自动调节油膜厚度,并能提高油膜刚度的用于回转工作台的静压导轨供油系统,为优化设计静压导轨供油系统打下了良好基础。
③对YD31125CNC6数控滚齿机闭式静压导轨工作参数进行理论计算,为静压导轨性能试验中的传感器选型提供重要参考。
④建立静压导轨的计算模型,运用FLUENT的前处理软件GAMBIT对静压导轨流场建模,对模型进行网格划分,并设定边界条件,利用流体分析软件FLUENT数值模拟了静态下静压导轨的油膜压力及流场分布,研究结果对静压导轨结构优化设计有指导意义。
⑤对大型数控滚齿机静压导轨进行力学性能试验研究,根据试验目的的要求设计制造静压导轨力学性能测试试验工作台,其中主要设计了加载机构并对其校核;设计了恒流量液压系统;对传感器进行了选型,并对其进行安装布置;开发了试验测量系统采集软件;然后按照制定的试验步骤进行试验,最后对试验结果进行了分析,试验研究成果对改进静压导轨力学性能具有重要的现实意义。
The hydrostatic slideway of worktable, of which mechanical properties can directly affect the machine’s quality, lifetime and operation efficiency, is the important component of the large CNC gear hobbing machine. With the development of modern industry, the tendency of extreme demands on aspect of speed and bearing of NC machine made the higher requirement to mechanical properties of the hydrostatic slideway. Therefore, it is necessary to conduct deeply research on the mechanical properties of the hydrostatic slideway on the basis of the theory analysis, simulation calculation, and scientific experiment so as to enhance the bearing capacity of worktable, extend the service life and raise process precision as well.
This paper mainly contains the following five contents:
Firstly, before analyzing the present research condition of hydrostatic technology at home and abroad, expound synthetically the features and significance of hydrostatic slideway. And then introduce the study’s object, content and major work.
Secondly, aiming at the condition that current fuel supply system hasn’t a upper adjusting accuracy of film thickness, a kind of self-adjusting film thickness is proposed, meanwhile a sort of fuel supply system of hydrostatic slideway that can be used to rotary table and increase the stiffness of film is designed, which builds up foundation of optimizing and designing the fuel supply system of hydrostatic slideway.
Thirdly, the closed hydrostatic slideway working parameters of the YD31125CNC6 is theoretically calculated to provide the vital reference for choosing sensors in the performance test of hydrostatic slideway.
Fourthly, the pre-processing software of FLUENT is used to set up the flow field model of hydrostatic slideway after the calculation model established. Then, do the mesh generation and set the boundary condition. In addition, the FLUENT is adopted to make the numerical simulation on the film pressure and flow field distribution in static environment. These results of study make sense to enlighten the optimal design about the structure of hydrostatic slideway.
Finally, research the mechanical properties test of the hydrostatic slideway of the large CNC gear hobbing machine. According to the test purpose, the test worktable used to do the mechanical properties test of hydrostatic slideway is designed, which includes the design and checking of the loading mechanism, the design of the constant flow hydraulic system, the choice and installation of sensors, and the development of the acquisition software for testing system. After that, do the test depending on the test’s steps and analyze the result which demonstrates the significant reality meaning to improve the slideway mechanical properties.
本文主要包括以下几部分内容:
①首先综合论述了液体静压导轨的特点及研究意义,然后分析了国内外静压技术发展应用的历史及现状,最后介绍了本文的研究目的、内容和主要工作。
②针对现有供油系统油膜厚度调节精度不高,实时补偿调节能力不强的问题,对其进行改进,提出一种工作压力高、能自动调节油膜厚度,并能提高油膜刚度的用于回转工作台的静压导轨供油系统,为优化设计静压导轨供油系统打下了良好基础。
③对YD31125CNC6数控滚齿机闭式静压导轨工作参数进行理论计算,为静压导轨性能试验中的传感器选型提供重要参考。
④建立静压导轨的计算模型,运用FLUENT的前处理软件GAMBIT对静压导轨流场建模,对模型进行网格划分,并设定边界条件,利用流体分析软件FLUENT数值模拟了静态下静压导轨的油膜压力及流场分布,研究结果对静压导轨结构优化设计有指导意义。
⑤对大型数控滚齿机静压导轨进行力学性能试验研究,根据试验目的的要求设计制造静压导轨力学性能测试试验工作台,其中主要设计了加载机构并对其校核;设计了恒流量液压系统;对传感器进行了选型,并对其进行安装布置;开发了试验测量系统采集软件;然后按照制定的试验步骤进行试验,最后对试验结果进行了分析,试验研究成果对改进静压导轨力学性能具有重要的现实意义。
The hydrostatic slideway of worktable, of which mechanical properties can directly affect the machine’s quality, lifetime and operation efficiency, is the important component of the large CNC gear hobbing machine. With the development of modern industry, the tendency of extreme demands on aspect of speed and bearing of NC machine made the higher requirement to mechanical properties of the hydrostatic slideway. Therefore, it is necessary to conduct deeply research on the mechanical properties of the hydrostatic slideway on the basis of the theory analysis, simulation calculation, and scientific experiment so as to enhance the bearing capacity of worktable, extend the service life and raise process precision as well.
This paper mainly contains the following five contents:
Firstly, before analyzing the present research condition of hydrostatic technology at home and abroad, expound synthetically the features and significance of hydrostatic slideway. And then introduce the study’s object, content and major work.
Secondly, aiming at the condition that current fuel supply system hasn’t a upper adjusting accuracy of film thickness, a kind of self-adjusting film thickness is proposed, meanwhile a sort of fuel supply system of hydrostatic slideway that can be used to rotary table and increase the stiffness of film is designed, which builds up foundation of optimizing and designing the fuel supply system of hydrostatic slideway.
Thirdly, the closed hydrostatic slideway working parameters of the YD31125CNC6 is theoretically calculated to provide the vital reference for choosing sensors in the performance test of hydrostatic slideway.
Fourthly, the pre-processing software of FLUENT is used to set up the flow field model of hydrostatic slideway after the calculation model established. Then, do the mesh generation and set the boundary condition. In addition, the FLUENT is adopted to make the numerical simulation on the film pressure and flow field distribution in static environment. These results of study make sense to enlighten the optimal design about the structure of hydrostatic slideway.
Finally, research the mechanical properties test of the hydrostatic slideway of the large CNC gear hobbing machine. According to the test purpose, the test worktable used to do the mechanical properties test of hydrostatic slideway is designed, which includes the design and checking of the loading mechanism, the design of the constant flow hydraulic system, the choice and installation of sensors, and the development of the acquisition software for testing system. After that, do the test depending on the test’s steps and analyze the result which demonstrates the significant reality meaning to improve the slideway mechanical properties.
引文
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[2]金秋颖.液体静压转台系统油膜工作性能分析[D].北京工业大学工学,2010.5.
[3]张晓彤.开式液体静压导轨油膜厚度控制方案的研究[D].哈尔滨理工大学工学,2007.3.
[4]于晓东.重型静压推力轴承力学性能及油膜态数值模拟研究[D],东北林业大学,2007.3.
[5]周桂茹.流体润滑理论[M].北京:机械工业出版社,1986.
[6]郭大威等.滑动轴承的失效分析[M].北京:机械工业出版社,1985.
[7]徐铮.专用磨床静压支承系统分析与仿真[D].甘肃:兰州理工大学.2009.5
[8]王勇勤,王荆,江桂云等.高精度动静压油膜轴承设计方法研究[J].重庆工学院学报, 2006, 20 (5) : 5-8.
[9]孙学志.液体静压导轨对置油垫承载能力及刚度的优化设计[J].航空精密制造技术,2005, 41(1):416.
[10]陈皓生,陈大融,江家道,李永健.粗糙表面滑动轴承非牛顿介质润滑的计算[J].摩擦学学报.2005.
[11]李宇辉.液体静压轴承在专用机床改装中的应用及应注意的问题[J].润滑与密封,2003(5):108-111.
[12]张晓彤.开式液体静压导轨油膜厚度控制方案的研究[D].哈尔滨理工大学工学,2007.3.
[13]李炳键.液体静压导轨在机床中的应用[J].山西机械,2003 , (3 ) : 46-47.
[14] Z.S.Safar and C.D.Mote,Jr.Analysis of Hydrostatic Thrust Bearings under Non-Axisymmetric Operation[J] .Wear. Volume 61,Issue 1,2 June 1980,P9一20.
[15] T.Jayachandra Prabhu and N.Ganesan .Analysis of Multirecess Conical Hydrostatic Thrust Bearings under Rotation[J]. Wear. Volume89, Issue 2,August 1983, P29-40.
[16] C.K.Singh and D.VSingh .The Design of High Speed Grease Imbricated Spindles for Machine Tool Production Equipment.SAE Transactions,1990,99(5):1061-1070.
[17] Hydrostatic Thrust Bearing[J] .Wear. Volume44, Issue 2,September 1977,P223-230.
[18] Johnson, Robert E.; Manring, Noah D. sensitivity Studies for the Shallow-Pocket Geometry of a Hydrostatic Thrust Bearing[J]. American Society of Mechanical Engineers,The Fluid Power and Systems Technology Division (Publication) FPST, v 10, 2003, P231-238.
[19] Satish C.Sharama,S.C.Jain and D.K.Bharuka .Influence of Recess Shape on the Performance of a Capillary Compensated Circular Thrust Pad Hydrostatic Bearing[J]. Tribology International Volume 35, Issue6,June 2002,P347-356.
[20] T.Jayachandra Prabhu and N.Ganesan .Analysis of Multirecess Conical Hydrostatic ThrustBearings under Rotation[J]. Wear. Volume89, Issue 2,August 1983, P29-40.
[21]崔凤奎等.液体静压和动静压滑动轴承设计[M].江苏:东南大学出版社,1998.
[22]刘大全.考虑温粘热效应的滑动轴承非线性油膜力模型研究及其应用[D].复旦大学博士论文.2005.
[23]张永学等.缝隙节流浮环动静压推力轴承紊流有限元分析[J].郑州大学学报(工学版),2002.
[24]胡玉兴.液压传动[M].北京:中国铁道出版社,1980. 9.
[25]王东锋.液体静压导轨及其设计研究[J].润滑与密封,2004, (4): 117-119.
[26]丁振乾.流体静压支承设计[M].上海:上海科学技术出版社,1989: 172-179.
[27]张晓彤.开式液体静压导轨油膜厚度控制方案的研究[D].哈尔滨理工大学工学,2007.3.
[28]广州机床研究所.液体静压技术原理及应用[M].北京:机械工业出版社,1978:99-101.
[29]张晓彤.开式液体静压导轨油膜厚度控制方案的研究[D],哈尔滨理工大学工学硕士学位论文,2007.3.
[30]胡竞湘.φ1.6米圆台立式磨床采用恒流静压导轨的研制[J].机床与液压,1999, (3): 69-70.
[31]刘德江.预载恒流静压导轨在CX5220立车上的应用[J].制造技术与机床,1994, (11): 21-22.
[32]孟心斋.恒流供油液静压支承静态性能新表达式与应用[J].洛阳工学院学报,2002, (1): 61-64.
[33]陈燕生.静压支承原理和设计[M] .北京:国防工业出版社,1980.
[34]王福军.计算流体力学分析—CFD软件原理与应用[M].北京:清华大学出版社,2004.9.
[35]朱自强等编著.应用计算流体力学[M].北京:北京航空航天大学出版社,1998: 2-5.
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