液体火箭发动机喷管螺旋槽数控加工技术
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摘要
以液氧/煤油为推进剂的主推/助推发动机和空间姿控发动机是我国最新型号的液体火箭发动机,其燃烧室收敛-扩张段喷管的冷却通道为等倾角螺旋槽或变倾角变导程螺旋槽。该类零件呈现母线复杂、刚度低的特征,加工困难。因此,研究满足液体火箭发动机螺旋槽生产要求的数控加工和自动编程技术是必要的。
基于微分几何原理推导了变倾角变导程螺旋槽的一般数学模型,分析了当螺旋倾角遵循常数、线性、抛物线规律变化时导程与螺旋角的函数关系。利用MATLAB软件计算获得了螺旋线离散数据,在UG环境中构建了直母线、凸／凹圆弧、样条母线回转面变倾角变导程螺旋槽实体模型,验证了其可加工性。
基于等倾角螺旋线的数学模型、运动解析以及四轴联动的加工原理,利用VC++6.0开发了一套Windows环境下的等倾角螺旋槽数控加工自动编程系统。该系统包括系统初始化模块、轮廓选择及数据处理模块、仿真及图形显示模块和NC代码生成模块,其中轮廓选择和数据处理模块是核心部分。该自动编程系统可以处理直线型、圆弧型、高次曲线型和离散点型等四种典型喷管母线,并且具有不同母线线型的自动拼接功能。只要初始化相应轮廓段的参数,系统在可连续输入的模式下完成型值点计算和轮廓拼接,并在图形仿真和显示模块中检验轮廓参数是否正确。利用等弦高差法分别计算每段轮廓螺旋槽上的刀位点,并生成数控加工NC代码。
在做论文期间,作者曾到机床使用厂家对所开发的等倾角螺旋槽数控加工自动编程系统进行了试验验证,实际应用表明,自动编程系统具有编程效率高、可靠稳定等优点。
The master push engines or the booster engines and the space attitude control engines using lox/kerosene as the propellant are China's latest model of liquid rocket engine. Coolant channel of the combustion chamber's convergent-divergent nozzle is loxodrome helical groove or changed angle and variable lead helical groove. The helical groove is difficult to be machined for the complexity of the component's generatrix and low stiffness. So it's quite necessary to explore and research new manufacturing and numerical control techniques suitable for the helical coolant groove for the liquid rocket engine.
Based on the principle of Differential Geometry, the text developed the mathematical model for changed angle and variable lead helical groove and analysed the function relationship between lead and helical angle in case of changes of the helical angle follow constant, linear and parabolic law. Furthermore, the spiral reinforcement discrete data was calculated through Matlab software. Finally, some new solid models of variable angle and variable lead helical groove revolution surface with straight generatrix, circular arc and spline generatrix were constructed within the UG circumstances.
According to the mathematical model, movement analysis and 4-axis-simulatanous-move machining method for the loxodrome, an auto-programming system for loxodrome helical groove NC machining based on Windows using VC++ 6.0. This system includes initialization module, contour selection and data processing module, simulation and graphic display module and code generation module, among which the contour selection and data processing module is the hard core. The auto-programming system with curve auto-stitiching function can handle four typical contours:linear type, circular arc type, High-order curve-type and discrete point-type. As long as the parameter of corresponding contour segment is initialized, the system could finish data points calculation and contour splicing under continuous input mode, and check out whether the contour parameters is right in simulation and graphic display module. It also could calculate the Cutter Location separately on each contour spiral groove, using equal chord height error algorithm, and generate the NC code for numerical control manufacturing.
The auto-programming system is testified to be efficient and stable through the writer' experimental verification in factories utilizing this system during the thesis's writing.
基于微分几何原理推导了变倾角变导程螺旋槽的一般数学模型,分析了当螺旋倾角遵循常数、线性、抛物线规律变化时导程与螺旋角的函数关系。利用MATLAB软件计算获得了螺旋线离散数据,在UG环境中构建了直母线、凸／凹圆弧、样条母线回转面变倾角变导程螺旋槽实体模型,验证了其可加工性。
基于等倾角螺旋线的数学模型、运动解析以及四轴联动的加工原理,利用VC++6.0开发了一套Windows环境下的等倾角螺旋槽数控加工自动编程系统。该系统包括系统初始化模块、轮廓选择及数据处理模块、仿真及图形显示模块和NC代码生成模块,其中轮廓选择和数据处理模块是核心部分。该自动编程系统可以处理直线型、圆弧型、高次曲线型和离散点型等四种典型喷管母线,并且具有不同母线线型的自动拼接功能。只要初始化相应轮廓段的参数,系统在可连续输入的模式下完成型值点计算和轮廓拼接,并在图形仿真和显示模块中检验轮廓参数是否正确。利用等弦高差法分别计算每段轮廓螺旋槽上的刀位点,并生成数控加工NC代码。
在做论文期间,作者曾到机床使用厂家对所开发的等倾角螺旋槽数控加工自动编程系统进行了试验验证,实际应用表明,自动编程系统具有编程效率高、可靠稳定等优点。
The master push engines or the booster engines and the space attitude control engines using lox/kerosene as the propellant are China's latest model of liquid rocket engine. Coolant channel of the combustion chamber's convergent-divergent nozzle is loxodrome helical groove or changed angle and variable lead helical groove. The helical groove is difficult to be machined for the complexity of the component's generatrix and low stiffness. So it's quite necessary to explore and research new manufacturing and numerical control techniques suitable for the helical coolant groove for the liquid rocket engine.
Based on the principle of Differential Geometry, the text developed the mathematical model for changed angle and variable lead helical groove and analysed the function relationship between lead and helical angle in case of changes of the helical angle follow constant, linear and parabolic law. Furthermore, the spiral reinforcement discrete data was calculated through Matlab software. Finally, some new solid models of variable angle and variable lead helical groove revolution surface with straight generatrix, circular arc and spline generatrix were constructed within the UG circumstances.
According to the mathematical model, movement analysis and 4-axis-simulatanous-move machining method for the loxodrome, an auto-programming system for loxodrome helical groove NC machining based on Windows using VC++ 6.0. This system includes initialization module, contour selection and data processing module, simulation and graphic display module and code generation module, among which the contour selection and data processing module is the hard core. The auto-programming system with curve auto-stitiching function can handle four typical contours:linear type, circular arc type, High-order curve-type and discrete point-type. As long as the parameter of corresponding contour segment is initialized, the system could finish data points calculation and contour splicing under continuous input mode, and check out whether the contour parameters is right in simulation and graphic display module. It also could calculate the Cutter Location separately on each contour spiral groove, using equal chord height error algorithm, and generate the NC code for numerical control manufacturing.
The auto-programming system is testified to be efficient and stable through the writer' experimental verification in factories utilizing this system during the thesis's writing.
引文
[1]张贵田.液氧/煤油液体火箭发动机的应用与发展前景.中国航天.1994,(8)：39-41.
[2]钟卫平.火箭喷管四轴联动数控加工自动编程系统的理论研究与软件开发：(硕士学位论文)太连.大连理工大学.1997.
[3]刘井玉,孙春华,刘华明.特种回转面铣刀螺旋槽的数控磨削模型及仿真[J].哈尔滨工业大学学报,1999,31(6)：116-118.
[4]Wang Y Q, Lu J C, Tong Y. Technology of loxodrome coolant channel machining on liquid rocket engine[J]. Journal of Astronautics,2003,24(3):322-326.
[5]单继宏, 孙毅, 李克彬.变导程螺旋面的算法及建模方法研究[J].东华大学学报,2005,31(4)：92-93.
[6]王永青.新型液体火箭发动机燃烧室内壁外表面等倾角螺旋槽加工技术的研究,(博士学位论文).大连：大连理工大学.2002.
[7]Kang S K, Ehmann K F, Lin C. A CAD approach to helical groove machining-I. Mathematical model and model solution[J]. International Journal of Machine Tools and Manufacture, 1996,36(1):141-153.
[8]Kang S K, Ehmann K F, Lin C. A CAD approach to helical groove machining. Paty2:Numerical evaluation and sensitivity analysis. International Journal of Machine Tools and Manufacture,1997,37(1):101-117.
[9]Cai w, He Y X, Li C X. A manufacturing model of helical groove on rotary burr and a universal post processing method[J]. International Journal Advanced Manufacture Technology,2006, (29):9-16.
[10]王增强,蔺小军,史耀耀等.回转曲面螺旋槽数控加工技术研究[J].机械科学与技术,2007,26(4)：428-430.
[11]孟莉.刘媛.王金泉.自动编程与手工编程探讨.现代制造工程.2006(8)：30-32.
[12]黄志荣,戴惠良.浅谈现代数控编程技术.东华大学学报.2004,30(6)：125-129.
[13]王敏杰,于同敏,郭东明.中国模具工程大典.北京：机械工业出版社,2004.
[14]龚智辉等.螺旋角的广义定义及其应用.中国机械工程,1994,5(1)：14-15.
[15]梅向明,黄敬之编著.微分几何.北京：高等教育出版社,2003.
[16]同济大学数学教研室编著.高等数学.北京：高等教育出版社,2000.
[17]范金.王永青.卢杰持.火箭发动机喷管螺旋槽加工方法的研究.大连理工大学学报.1999,39(3)：420-424.
[18]关治,陈景良.数值计算方法.北京：清华大学出版社,1998：126-135.
[19]方群等.中国航天科技集团7103厂赴俄罗斯考察报告.1995.
[20]全荣等.五坐标联动数控技术.长沙：湖南科学技术出版社,1995.
[21]范炳炎等.数控加工程序编制.北京：航空工业出版社,1990.
[22]林奕鸿等.机床数控技术及其应用.机械工业出版社,1994.
[23]李佳等.集成CAD/CAM中五轴NC加工后处理关键技术研究.天津大学学报.1998,31(3)：284-289
[24]钱能.C++程序设计教程.北京：清华大学出版社,1999.
[25]周鸣杨,于秋生等.Visual C++程序设计教程.北京：机械工业出版社,2004.
[2]钟卫平.火箭喷管四轴联动数控加工自动编程系统的理论研究与软件开发：(硕士学位论文)太连.大连理工大学.1997.
[3]刘井玉,孙春华,刘华明.特种回转面铣刀螺旋槽的数控磨削模型及仿真[J].哈尔滨工业大学学报,1999,31(6)：116-118.
[4]Wang Y Q, Lu J C, Tong Y. Technology of loxodrome coolant channel machining on liquid rocket engine[J]. Journal of Astronautics,2003,24(3):322-326.
[5]单继宏, 孙毅, 李克彬.变导程螺旋面的算法及建模方法研究[J].东华大学学报,2005,31(4)：92-93.
[6]王永青.新型液体火箭发动机燃烧室内壁外表面等倾角螺旋槽加工技术的研究,(博士学位论文).大连：大连理工大学.2002.
[7]Kang S K, Ehmann K F, Lin C. A CAD approach to helical groove machining-I. Mathematical model and model solution[J]. International Journal of Machine Tools and Manufacture, 1996,36(1):141-153.
[8]Kang S K, Ehmann K F, Lin C. A CAD approach to helical groove machining. Paty2:Numerical evaluation and sensitivity analysis. International Journal of Machine Tools and Manufacture,1997,37(1):101-117.
[9]Cai w, He Y X, Li C X. A manufacturing model of helical groove on rotary burr and a universal post processing method[J]. International Journal Advanced Manufacture Technology,2006, (29):9-16.
[10]王增强,蔺小军,史耀耀等.回转曲面螺旋槽数控加工技术研究[J].机械科学与技术,2007,26(4)：428-430.
[11]孟莉.刘媛.王金泉.自动编程与手工编程探讨.现代制造工程.2006(8)：30-32.
[12]黄志荣,戴惠良.浅谈现代数控编程技术.东华大学学报.2004,30(6)：125-129.
[13]王敏杰,于同敏,郭东明.中国模具工程大典.北京：机械工业出版社,2004.
[14]龚智辉等.螺旋角的广义定义及其应用.中国机械工程,1994,5(1)：14-15.
[15]梅向明,黄敬之编著.微分几何.北京：高等教育出版社,2003.
[16]同济大学数学教研室编著.高等数学.北京：高等教育出版社,2000.
[17]范金.王永青.卢杰持.火箭发动机喷管螺旋槽加工方法的研究.大连理工大学学报.1999,39(3)：420-424.
[18]关治,陈景良.数值计算方法.北京：清华大学出版社,1998：126-135.
[19]方群等.中国航天科技集团7103厂赴俄罗斯考察报告.1995.
[20]全荣等.五坐标联动数控技术.长沙：湖南科学技术出版社,1995.
[21]范炳炎等.数控加工程序编制.北京：航空工业出版社,1990.
[22]林奕鸿等.机床数控技术及其应用.机械工业出版社,1994.
[23]李佳等.集成CAD/CAM中五轴NC加工后处理关键技术研究.天津大学学报.1998,31(3)：284-289
[24]钱能.C++程序设计教程.北京：清华大学出版社,1999.
[25]周鸣杨,于秋生等.Visual C++程序设计教程.北京：机械工业出版社,2004.