基于正弦机构的曲轴复合车削刀架系统的研究
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摘要
曲轴加工复合车床通过随动车削的方式对曲轴连杆轴颈进行加工。本文拟采用正弦刀架机构来实现随动车削。通过对随动车削曲轴连杆轴颈的过程进行分析计算,总结出能够完成随动车削的两个必要条件。利用ADAMS软件对正弦刀架机构和曲轴组成的系统进行仿真,计算出刀尖点在切削运动过程中的轨迹,证明正弦机构满足随动车削的两个必要条件。接着将进一步对刀尖点相对于连杆轴颈表面上点的相对运动进行研究,当曲轴和刀架机构同步转动时,得到了刀尖点绕曲轴连杆轴颈做圆周运动,而且圆的半径刚好等于轴颈的半径。根据上面的研究可以说明正弦刀架机构可以完成曲轴连杆轴颈的随动车削。
刀架的曲柄长度必须等于曲轴的曲柄长度,加工不同类型的曲轴时,就要对刀架的曲轴长度进行调整。经过分析,确定了曲柄长度调整方式,将曲柄截断并通过转动副进行连接,然后利用机构自身转动来实现自动调整。对具体的调整过程进行了分析,同时完成了曲柄转动角的计算。对导轨进行选择,并计算导轨在工作状态下的受力,以此为依据进行导轨寿命的计算。完成刀架机构的总体结构设计,通过Pro/E软件建立刀架的三维模型。
对正弦机构进行运动学分析,求解出正弦机构各个部件的速度、加速度表达式。利用ADAMS软件进行虚拟仿真,验证运动学分析的结果,并对运动过程中产生的惯性力进行分析。根据仿真分析的结果提出刀架机构动平衡的总体方案,进行动平衡装置的设计,最后利用ADAMS软件分析安装了动平衡装置后的刀架机构的惯性力,以验证动平衡装置的效果,仿真结果表明动平衡装置能够平衡刀架机构的惯性力,达到了预期的效果。
对刀架机构中的重要部件进行有限元分析。计算刀盘在载荷作用下所产生的节点位移、应力、应变情况,对得出的位移、应力、应变云图进行分析。对刀盘进行模态分析,得出刀盘的固有频率以及振型等动态特性。分析结果表明刀盘满足设计要求。上述分析结果可以为刀盘的结构改进和结构优化提供参考依据。
The crankshaft machining complex lathe turned the crank arm journal with the way of servo turning methods. The lathe used sine mechanism to achieve servo turning. By analyzed the processing of servo turning,two necessary conditions of completing the servo cutting was Summed up. Using the ADAMS software to simulate the system composed of sine turret mechanism and crankshaft in order to calculate the trajectory of the tip point in the process of cutting motion and prove the sine mechanism to meet the two necessary conditions for servo turning. After that, it did further study on relative motion between vertex of tool and point of the crank arm journal by using ADAMS software. When the crankshaft and tool mount mechanism made synchronous rotation, the trajectory of vertex of tool was also a circle which had the same radius as crank arm journal. All this study concluded that the sine mechanism could finish the turning methods of the crank arm.
The crank of Turret must equal to the length of side arm of crankshaft, it need to change the length of crank of turret when processed different crankshaft. The way of changing the length of crank had been determined. The crank had been interrupted and been connection with rotation pair, then it made change by changing the positional relationship of two parts. Specific adjustment processing had been analyzed, and the rotation angle of crank had been calculated at the same time. At last completing the design of the turret, and establishing the three-dimensional model of the turret in Pro/E software.
Do the kinematical analysis of the sine institutions to solve the speed and acceleration of every parts of the sine institutions. The three-dimensional model of turret should be imported into ADAMS software. Then, do the virtual simulation, to verify the results of kinematical analysis, and do the analysis of the inertia force of the movement. According to the results of the simulation analysis of the turret, we should determine the overall program of body balancing and design the dynamic balancing device. Finally, the three-dimensional of turret installed the inertia force balancing device was imported into ADAMS software in order to verify the effect of balancing devices, and the results of the simulation should be evaluated.
Did the finite element analysis of important parts of the turret, and calculated the displacement and stress and strain of nodes of cutter. We also did the modal analysis, and calculated the natural frequency and the modes of the cutter.At last, we should evaluate the results of finite element analysis and the results show that the design of the cutter is reasonable.All the results can provide a reference for structural improvements.
刀架的曲柄长度必须等于曲轴的曲柄长度,加工不同类型的曲轴时,就要对刀架的曲轴长度进行调整。经过分析,确定了曲柄长度调整方式,将曲柄截断并通过转动副进行连接,然后利用机构自身转动来实现自动调整。对具体的调整过程进行了分析,同时完成了曲柄转动角的计算。对导轨进行选择,并计算导轨在工作状态下的受力,以此为依据进行导轨寿命的计算。完成刀架机构的总体结构设计,通过Pro/E软件建立刀架的三维模型。
对正弦机构进行运动学分析,求解出正弦机构各个部件的速度、加速度表达式。利用ADAMS软件进行虚拟仿真,验证运动学分析的结果,并对运动过程中产生的惯性力进行分析。根据仿真分析的结果提出刀架机构动平衡的总体方案,进行动平衡装置的设计,最后利用ADAMS软件分析安装了动平衡装置后的刀架机构的惯性力,以验证动平衡装置的效果,仿真结果表明动平衡装置能够平衡刀架机构的惯性力,达到了预期的效果。
对刀架机构中的重要部件进行有限元分析。计算刀盘在载荷作用下所产生的节点位移、应力、应变情况,对得出的位移、应力、应变云图进行分析。对刀盘进行模态分析,得出刀盘的固有频率以及振型等动态特性。分析结果表明刀盘满足设计要求。上述分析结果可以为刀盘的结构改进和结构优化提供参考依据。
The crankshaft machining complex lathe turned the crank arm journal with the way of servo turning methods. The lathe used sine mechanism to achieve servo turning. By analyzed the processing of servo turning,two necessary conditions of completing the servo cutting was Summed up. Using the ADAMS software to simulate the system composed of sine turret mechanism and crankshaft in order to calculate the trajectory of the tip point in the process of cutting motion and prove the sine mechanism to meet the two necessary conditions for servo turning. After that, it did further study on relative motion between vertex of tool and point of the crank arm journal by using ADAMS software. When the crankshaft and tool mount mechanism made synchronous rotation, the trajectory of vertex of tool was also a circle which had the same radius as crank arm journal. All this study concluded that the sine mechanism could finish the turning methods of the crank arm.
The crank of Turret must equal to the length of side arm of crankshaft, it need to change the length of crank of turret when processed different crankshaft. The way of changing the length of crank had been determined. The crank had been interrupted and been connection with rotation pair, then it made change by changing the positional relationship of two parts. Specific adjustment processing had been analyzed, and the rotation angle of crank had been calculated at the same time. At last completing the design of the turret, and establishing the three-dimensional model of the turret in Pro/E software.
Do the kinematical analysis of the sine institutions to solve the speed and acceleration of every parts of the sine institutions. The three-dimensional model of turret should be imported into ADAMS software. Then, do the virtual simulation, to verify the results of kinematical analysis, and do the analysis of the inertia force of the movement. According to the results of the simulation analysis of the turret, we should determine the overall program of body balancing and design the dynamic balancing device. Finally, the three-dimensional of turret installed the inertia force balancing device was imported into ADAMS software in order to verify the effect of balancing devices, and the results of the simulation should be evaluated.
Did the finite element analysis of important parts of the turret, and calculated the displacement and stress and strain of nodes of cutter. We also did the modal analysis, and calculated the natural frequency and the modes of the cutter.At last, we should evaluate the results of finite element analysis and the results show that the design of the cutter is reasonable.All the results can provide a reference for structural improvements.
引文
[1]李海国.曲轴先进制造技术及工艺应用研究[J].现代制造技术与装备,2007,(4)：5-8+26.
[2]李海国.发动机曲轴制造技术新动向[J].制造技术与机床,2006,(1)：27-29.
[3]刘丽秋.曲轴加工技术及其特点[J].机械设计与制造,1997,(4)：46.
[4]王仲.曲轴粗加工关键工艺及设备的比较[J].内燃机,2003,(1)：23-24+28.
[5]顾永生.曲轴主轴颈和连杆轴颈的粗加工工艺分析[J].世界制造技术与装备市场,2002.(4)：44-47.
[6]李须峰.发动机曲轴加工的新工艺及装备[J].现代零部件,2006,(9)：87-89.
[7]王晓兰.我国发动机曲轴制造的发展趋势[J].内江科技,2007,(8)：140-144.
[8]李建强.曲轴加工工艺及设备[J].现代零部件,2010,(9)：22-23.
[9]汤晓宇.汽车加工曲轴加工技术[J].汽车工艺与材料,2007,(6)：25-36.
[10]杨厚忠.曲轴工艺发展及研究[J].制造技术及材料,2010,(10)：19-21.
[11]李海国.曲轴加工工艺的发展演变及柔性生产线[J].重型机械科技,2001,(3)：1-4+15.
[12]周玮.曲轴加工工艺分析[J].机电产品开发与创新,2010,(3)：191-192.
[13]周来宏.曲轴加工工艺及内铣技术的研究：[硕士学位论文].大连：大连交通大学,2008.
[14]李海国.曲轴加工技术走向高效复合化[J].MC现代零件,2006,(2)：50-54.
[15]黄应勇.微型汽车曲轴加工工艺探究[J].沿海企业与科技,2010,(9)：25-27.
[16]王一冶.介绍几种曲轴加工的先进技术[J].机械制造,1996,(11)：25-27.
[17]刘丽秋.曲轴加工技术及其特点[J].机械设计与制造,1997.(4)：45-46.
[18]李井会.曲轴制造工艺综述[J].船舶工业技术经济信息,2002.(7)：29-34.
[19]周德生.曲轴加工新技术[J].机械工人,2004,(5)：17-21.
[20]张胜军.曲轴车拉加工方法研究及刀盘方案设计：[硕士学位论文].武汉：武汉理工大学,2008.
[21]陈艳丽.基于车铣的曲轴精加工的研究：[硕士学位论文].洛阳：洛阳理工大学,2008.
[22]李国海,张小菊.发动机曲轴高效加工技术的应用与进展.机械工人,2007(5)：32-34
[23]赵钢.内燃机曲轴制造技术现状及发展趋势.内燃机,2004(3)：34-38
[24]梁华春,汪怀伦,梅碧丹,金宁.曲轴偏心轴颈加工工艺方案探讨.锻压装备与制造技 术,2009(1)：30-31
[25]许梅,孙军,石清辉.曲轴连杆颈的随动磨削.山东内燃机,2004(3)：34-38
[26]张书桥.发动机曲轴加工的新工艺及装备.现代零部件,2006(9)：87-89
[27]赵长明.数控车拉工艺在一气大众的应用.自动化加工技术,2006(5)：43-45.
[28]杨宏武.高速随动数控曲轴磨削原理及若干关键技术研究[D].武汉理工大学硕士学位论文,2007
[29]高广阔,刘景峰,辜祖勋.轿车发动机曲轴材料及工艺的研究.汽车工艺与材料,2005(6)：3-9
[30]姬文芳.机床夹具设计.航空工业出版社,1994,3
[31]张耀寰.机械加工工艺手册.航天工业出版社,1987,12
[32]成大先.机械设计手册第四版.化学工业出版社,2004,9
[33]Niino.Tadashi,Iwamoto.Tatsuya,Ueda.Shingo.Development of simulation technology for dynamic behavior of crankshaft systems in motorcycle engines[J]. JSAE Review,2002.23(1):127-131.
[34]Hirahara,Hiroo;Yoshida,Keita;Iwase, Masami.Torque estimation based on nonlinear engine model considering crankshaft torsion.2010 IEEE/ASME International Conference on Advanced Intelligent Mechatronics, AIM 2010.682-687.
[35]Liu,Rongchang;Ma,Shuying;Chen,Xiuhong;Xue,Longquan;Dong,Litao.Theoretical model and loading analysis of crankshaft fillet rolling. Proceedings of the International Conference on Information Management Proceedings of the International Conference on Information Management, Innovation Management and Industrial Engineering, ICIII 2008.2008(3):440-444.
[36]Dong,Dan-Dan;Qin,Wen-Jie;Liu,Jin-Xiang. Analysis and comparison on two kinds of crankshaft balance method for in-line 6-cylinder engines[J]. Neiranji Gongcheng,2006.4(27):39-42
[37]Fonte,M.;de Freitas,M. Marine main engine crankshaft failure analysis:A case study[J]. Engineering Failure Analysis,2009(16):1940-1947.
[38]Bai,Shu-Zhan;Li,Guo-Xiang;Zhang,Xi-Chao. Crankshaft front-end vibration analysis of a vehicle engine[J]. Journal of Vibration and Shock,2007.2(26):167-170.
[39]Kong,De-Jun;Sun,Bo;Zhu,Wei;Zhu,Hai-Lin. Experimental study on residual stresses of crankshaft chamfer with XRD[J]. Transactions of CSICE,2008.11(26):565-568.
[40]Kharitonov, L.V.; Markin, P.V.; Fedorov, E.A.; Katkov, I.S.; Rudalev, N.F. Technique for manufacturing blanks of large-size crankshafts for diesel engines. Kuznechno-Shtampovochnoe Proizvodstvo,26
[41]Sitta, Gerhard; Scheidtweiler, Lothar. Screwed Throw-away Cutting Tips on Circular Milling Cutters for Machining Crankshafts. Werkstatt und Betrieb,261-263
[42]Devegte VJ.New. Technology in machining of Crankshaft for Engine. Auto Manufaeturing Technology,2006(4):12-16
[43]Lee C W. Development of Turning-Broacking cutter for Crankshaft. Manufacturing Technology,2006(7):34-36
[44]Johns. Design for Nationalized Technique Crankshaft. Auto Manufacturing Technology, 2007(2):45-47
[45]DaPhne. Teehniques for Crankshaft Procsee. ASME,2004(3):45-47
[2]李海国.发动机曲轴制造技术新动向[J].制造技术与机床,2006,(1)：27-29.
[3]刘丽秋.曲轴加工技术及其特点[J].机械设计与制造,1997,(4)：46.
[4]王仲.曲轴粗加工关键工艺及设备的比较[J].内燃机,2003,(1)：23-24+28.
[5]顾永生.曲轴主轴颈和连杆轴颈的粗加工工艺分析[J].世界制造技术与装备市场,2002.(4)：44-47.
[6]李须峰.发动机曲轴加工的新工艺及装备[J].现代零部件,2006,(9)：87-89.
[7]王晓兰.我国发动机曲轴制造的发展趋势[J].内江科技,2007,(8)：140-144.
[8]李建强.曲轴加工工艺及设备[J].现代零部件,2010,(9)：22-23.
[9]汤晓宇.汽车加工曲轴加工技术[J].汽车工艺与材料,2007,(6)：25-36.
[10]杨厚忠.曲轴工艺发展及研究[J].制造技术及材料,2010,(10)：19-21.
[11]李海国.曲轴加工工艺的发展演变及柔性生产线[J].重型机械科技,2001,(3)：1-4+15.
[12]周玮.曲轴加工工艺分析[J].机电产品开发与创新,2010,(3)：191-192.
[13]周来宏.曲轴加工工艺及内铣技术的研究：[硕士学位论文].大连：大连交通大学,2008.
[14]李海国.曲轴加工技术走向高效复合化[J].MC现代零件,2006,(2)：50-54.
[15]黄应勇.微型汽车曲轴加工工艺探究[J].沿海企业与科技,2010,(9)：25-27.
[16]王一冶.介绍几种曲轴加工的先进技术[J].机械制造,1996,(11)：25-27.
[17]刘丽秋.曲轴加工技术及其特点[J].机械设计与制造,1997.(4)：45-46.
[18]李井会.曲轴制造工艺综述[J].船舶工业技术经济信息,2002.(7)：29-34.
[19]周德生.曲轴加工新技术[J].机械工人,2004,(5)：17-21.
[20]张胜军.曲轴车拉加工方法研究及刀盘方案设计：[硕士学位论文].武汉：武汉理工大学,2008.
[21]陈艳丽.基于车铣的曲轴精加工的研究：[硕士学位论文].洛阳：洛阳理工大学,2008.
[22]李国海,张小菊.发动机曲轴高效加工技术的应用与进展.机械工人,2007(5)：32-34
[23]赵钢.内燃机曲轴制造技术现状及发展趋势.内燃机,2004(3)：34-38
[24]梁华春,汪怀伦,梅碧丹,金宁.曲轴偏心轴颈加工工艺方案探讨.锻压装备与制造技 术,2009(1)：30-31
[25]许梅,孙军,石清辉.曲轴连杆颈的随动磨削.山东内燃机,2004(3)：34-38
[26]张书桥.发动机曲轴加工的新工艺及装备.现代零部件,2006(9)：87-89
[27]赵长明.数控车拉工艺在一气大众的应用.自动化加工技术,2006(5)：43-45.
[28]杨宏武.高速随动数控曲轴磨削原理及若干关键技术研究[D].武汉理工大学硕士学位论文,2007
[29]高广阔,刘景峰,辜祖勋.轿车发动机曲轴材料及工艺的研究.汽车工艺与材料,2005(6)：3-9
[30]姬文芳.机床夹具设计.航空工业出版社,1994,3
[31]张耀寰.机械加工工艺手册.航天工业出版社,1987,12
[32]成大先.机械设计手册第四版.化学工业出版社,2004,9
[33]Niino.Tadashi,Iwamoto.Tatsuya,Ueda.Shingo.Development of simulation technology for dynamic behavior of crankshaft systems in motorcycle engines[J]. JSAE Review,2002.23(1):127-131.
[34]Hirahara,Hiroo;Yoshida,Keita;Iwase, Masami.Torque estimation based on nonlinear engine model considering crankshaft torsion.2010 IEEE/ASME International Conference on Advanced Intelligent Mechatronics, AIM 2010.682-687.
[35]Liu,Rongchang;Ma,Shuying;Chen,Xiuhong;Xue,Longquan;Dong,Litao.Theoretical model and loading analysis of crankshaft fillet rolling. Proceedings of the International Conference on Information Management Proceedings of the International Conference on Information Management, Innovation Management and Industrial Engineering, ICIII 2008.2008(3):440-444.
[36]Dong,Dan-Dan;Qin,Wen-Jie;Liu,Jin-Xiang. Analysis and comparison on two kinds of crankshaft balance method for in-line 6-cylinder engines[J]. Neiranji Gongcheng,2006.4(27):39-42
[37]Fonte,M.;de Freitas,M. Marine main engine crankshaft failure analysis:A case study[J]. Engineering Failure Analysis,2009(16):1940-1947.
[38]Bai,Shu-Zhan;Li,Guo-Xiang;Zhang,Xi-Chao. Crankshaft front-end vibration analysis of a vehicle engine[J]. Journal of Vibration and Shock,2007.2(26):167-170.
[39]Kong,De-Jun;Sun,Bo;Zhu,Wei;Zhu,Hai-Lin. Experimental study on residual stresses of crankshaft chamfer with XRD[J]. Transactions of CSICE,2008.11(26):565-568.
[40]Kharitonov, L.V.; Markin, P.V.; Fedorov, E.A.; Katkov, I.S.; Rudalev, N.F. Technique for manufacturing blanks of large-size crankshafts for diesel engines. Kuznechno-Shtampovochnoe Proizvodstvo,26
[41]Sitta, Gerhard; Scheidtweiler, Lothar. Screwed Throw-away Cutting Tips on Circular Milling Cutters for Machining Crankshafts. Werkstatt und Betrieb,261-263
[42]Devegte VJ.New. Technology in machining of Crankshaft for Engine. Auto Manufaeturing Technology,2006(4):12-16
[43]Lee C W. Development of Turning-Broacking cutter for Crankshaft. Manufacturing Technology,2006(7):34-36
[44]Johns. Design for Nationalized Technique Crankshaft. Auto Manufacturing Technology, 2007(2):45-47
[45]DaPhne. Teehniques for Crankshaft Procsee. ASME,2004(3):45-47