光滑内螺旋曲面非典型成形铣削理论与应用技术研究
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摘要
螺杆钻具马达和螺杆泵是石油工业中广泛应用的螺旋机械,其定子和转子构成了一齿差啮合副,它们的设计和制造质量直接影响螺旋机械的各项性能指标。定子型线为摆线类曲线或其他二阶连续曲线,其工作型面为光滑内螺旋曲面。传统的定子是在金属圆筒的内壁注胶生成不等壁厚的橡胶层螺旋曲面；新型定子是在预加工有内螺旋曲面的金属定子内壁注胶生成等壁厚橡胶层螺旋曲面。使用新型的等橡胶壁厚定子可以大幅提高螺旋机械整机的综合性能和使用寿命。金属定子螺旋曲面的型线为定子工作型线的外等距线。本文针对金属定子光滑内螺旋曲面的非典型成形铣削理论和应用技术进行了深入的的研究。文章主要研究内容包括如下几个方面：
研究了根据定子橡胶层截面型线参数计算金属定子截面型线和金属定子内螺旋曲面的数学模型。研究了定子截面型线参数未知时,采用测量数据直接重构曲面的NURBS方法来获得金属定子内螺旋曲面模型的实体建模方法。
提出了一种全新的、不同于现有螺旋曲面典型切削加工的轴向定尺寸盘状铣刀非典型成形铣削方法。研究了该加工方法的成形原理和特点。针对特定的切削加工形式,建立了刀具工件的空间啮合轨迹和盘状成形铣刀廓形的计算模型。首先根据刀具和工件相对运动过程中的几何关系,研究采用几何解析算法求解的求解理论。然后提出了一种新的、基于等距切面法的离散数值算法,该算法无需研究大量预知几何条件,计算速度快,精度高。根据切屑成形机理,研究了刀具铣削力的预测方法,并采用有限元方法,对切削过程进行了模拟仿真。
针对轴向定尺寸盘状铣刀非典型成形铣削加工中的复杂刀具廓形设计问题,应用最小二乘圆弧逼近理论对刀具廓形进行了简化,并对简化近似误差进行了分析。针对圆弧刃形刀具所加工零件的截面型线进行了研究,提出了工件截面曲线的动态包络算法。通过分析其成形原理与成形运动轨迹,给出了该种方法的适用条件和干涉判定方法,分析了加工误差的形成机理。
将相关理论研究成果应用到螺杆钻具定子内螺旋曲面的加工制造中,对切削设备中的细长动力铣杆的导向与支撑、复杂深孔排屑、铣头的有限空间传动等关键技术问题进行了研究。针对以上理论研究,进行了多次切削试验,并对试验结果进行了分析。试验证明,理论研究成果正确可行,试验数据对切削设备优化和切削参数选择提供了有益支持。
本文研究工作,在理论上丰富了螺旋曲面,特别是内螺旋曲面的相关理论与分析手段。在方法创新上,提出了一种非典型定尺寸盘状铣刀成形铣削的加工方法,为提高内螺旋曲面类零件切削制造效率提供了新思路和新方法。在技术应用上,对于螺旋机械零部件制造行业广泛应用的内螺旋曲面零件切削机床的研制具有重要意义。
The screw drilling tool and the screw pump are widely used in the petroleum industry which is a kind of screw machinery. The stator and rotor compose one tooth difference meshing pair whose design and manufacturing quality will influence on many performances of the spiral machinery directly. The curve type of the stator is cycloid or other second-order continuous curve. So the work surface of the stator is smooth inner helical surface. The metal casing of traditional single screw's motor stator is an equal thickness cylinder, and an unequal thickness rubber bushing is vulcanized in the cylinder. The metal casing of the new-style stator is an unequal thickness cylinder with premade inner helicoid, and equal thickness rubber bushing is vulcanized in it. The new-style stator which has an equal thickness rubble bushing can substantially improve the performance and service life of the machine. The metal stator's cross section is equidistance curve of the working curve. In this paper, the forming theory and application technology of helical surfaces in the metal sleeve of the stator will be studied intensively. The major research works and contributions of the thesis are summarized as follows:
The mathematical model of the metal casing's cross section curves and of the helical surface for the stator have been deduced according to the principle of the equidistance curve when the rubber bushing curve style is known. Three-dimensional-entity modeling technology for the steel casing of the stator which is got by the measurement data of the stator using direct reconstruction of NURBS method when the rubber bushing curve style is unknown or is substituted by simple curve.
A fire-new cutting method is proposed which is different from existing cutting method for the inner helical surface, it is named with Axial-Fixed size-Atypical Form Milling. Based on the analysis of the typical form milling theory of the helical surface, the new atypical method is proposed and the principles and characteristics of the processing method are expounded. The space meshing trace of the tool and the workpiece and disc cutter profile algorithm are studied according to the atypical cutting format. Firstly, geometric resolution algorithm for solving theory of the profile shape of the tool is researched by the motion of the tool relative to the workpiece. Then, a new method based on equidistance section and discrete values is advanced. This method has a fast calculation speed and high precision, and the algorithm does not need a lot of predictable geometric conditions. Milling force prediction method is studied and the cutting process simulation is carried out on the software platform based on FEM according to the chip formation mechanism and material plasticity theory.
According to the Profile Design of complex cutter in the Axial-Fixed size-Atypical Form Milling, a approximate method based on piecewise least squares arc approximation theory of the tool profile shape approximating is brought forward. And the approximately error is also studied. Dynamic envelope algorithm is advanced to the calculate cross section curve of the workpiece according to different parameters of the tool edge shape in the event that its shape is arc. By the atypical forming principle and the shaping trajectory, the applicable conditions and the interference judgment method are given and the composition of the machining error is analyzed.
The research results of the theory are applied to the manufacturing of helical surfaces within the PDM stator in technical applications. Some of the key technical problems are studied such as the guide and support of the slender milling rod, chip removal in the complex and deep hole, limited space transmission of the milling head and so on. A number of cutting tests are conducted and test results are analyzed to verify the theoretical studies mentioned above. Test result has proved, the theoretical research is feasible and correct.
The studies enrich and expand the theory and analytic tools to the helical surfaces, especially to the inner helicoid surfaces. It bings forward a new atypical cutting method using a certain size disc-milling cutter which provides new ideas and new approaches to improve the helical surface parts cutting efficiency in the field of innovating approaches. It has major significance for the development of the cutting machine tools which can manufacture parts with inner helicoid surface widely used in spiral mechanical parts manufacturing industry.
研究了根据定子橡胶层截面型线参数计算金属定子截面型线和金属定子内螺旋曲面的数学模型。研究了定子截面型线参数未知时,采用测量数据直接重构曲面的NURBS方法来获得金属定子内螺旋曲面模型的实体建模方法。
提出了一种全新的、不同于现有螺旋曲面典型切削加工的轴向定尺寸盘状铣刀非典型成形铣削方法。研究了该加工方法的成形原理和特点。针对特定的切削加工形式,建立了刀具工件的空间啮合轨迹和盘状成形铣刀廓形的计算模型。首先根据刀具和工件相对运动过程中的几何关系,研究采用几何解析算法求解的求解理论。然后提出了一种新的、基于等距切面法的离散数值算法,该算法无需研究大量预知几何条件,计算速度快,精度高。根据切屑成形机理,研究了刀具铣削力的预测方法,并采用有限元方法,对切削过程进行了模拟仿真。
针对轴向定尺寸盘状铣刀非典型成形铣削加工中的复杂刀具廓形设计问题,应用最小二乘圆弧逼近理论对刀具廓形进行了简化,并对简化近似误差进行了分析。针对圆弧刃形刀具所加工零件的截面型线进行了研究,提出了工件截面曲线的动态包络算法。通过分析其成形原理与成形运动轨迹,给出了该种方法的适用条件和干涉判定方法,分析了加工误差的形成机理。
将相关理论研究成果应用到螺杆钻具定子内螺旋曲面的加工制造中,对切削设备中的细长动力铣杆的导向与支撑、复杂深孔排屑、铣头的有限空间传动等关键技术问题进行了研究。针对以上理论研究,进行了多次切削试验,并对试验结果进行了分析。试验证明,理论研究成果正确可行,试验数据对切削设备优化和切削参数选择提供了有益支持。
本文研究工作,在理论上丰富了螺旋曲面,特别是内螺旋曲面的相关理论与分析手段。在方法创新上,提出了一种非典型定尺寸盘状铣刀成形铣削的加工方法,为提高内螺旋曲面类零件切削制造效率提供了新思路和新方法。在技术应用上,对于螺旋机械零部件制造行业广泛应用的内螺旋曲面零件切削机床的研制具有重要意义。
The screw drilling tool and the screw pump are widely used in the petroleum industry which is a kind of screw machinery. The stator and rotor compose one tooth difference meshing pair whose design and manufacturing quality will influence on many performances of the spiral machinery directly. The curve type of the stator is cycloid or other second-order continuous curve. So the work surface of the stator is smooth inner helical surface. The metal casing of traditional single screw's motor stator is an equal thickness cylinder, and an unequal thickness rubber bushing is vulcanized in the cylinder. The metal casing of the new-style stator is an unequal thickness cylinder with premade inner helicoid, and equal thickness rubber bushing is vulcanized in it. The new-style stator which has an equal thickness rubble bushing can substantially improve the performance and service life of the machine. The metal stator's cross section is equidistance curve of the working curve. In this paper, the forming theory and application technology of helical surfaces in the metal sleeve of the stator will be studied intensively. The major research works and contributions of the thesis are summarized as follows:
The mathematical model of the metal casing's cross section curves and of the helical surface for the stator have been deduced according to the principle of the equidistance curve when the rubber bushing curve style is known. Three-dimensional-entity modeling technology for the steel casing of the stator which is got by the measurement data of the stator using direct reconstruction of NURBS method when the rubber bushing curve style is unknown or is substituted by simple curve.
A fire-new cutting method is proposed which is different from existing cutting method for the inner helical surface, it is named with Axial-Fixed size-Atypical Form Milling. Based on the analysis of the typical form milling theory of the helical surface, the new atypical method is proposed and the principles and characteristics of the processing method are expounded. The space meshing trace of the tool and the workpiece and disc cutter profile algorithm are studied according to the atypical cutting format. Firstly, geometric resolution algorithm for solving theory of the profile shape of the tool is researched by the motion of the tool relative to the workpiece. Then, a new method based on equidistance section and discrete values is advanced. This method has a fast calculation speed and high precision, and the algorithm does not need a lot of predictable geometric conditions. Milling force prediction method is studied and the cutting process simulation is carried out on the software platform based on FEM according to the chip formation mechanism and material plasticity theory.
According to the Profile Design of complex cutter in the Axial-Fixed size-Atypical Form Milling, a approximate method based on piecewise least squares arc approximation theory of the tool profile shape approximating is brought forward. And the approximately error is also studied. Dynamic envelope algorithm is advanced to the calculate cross section curve of the workpiece according to different parameters of the tool edge shape in the event that its shape is arc. By the atypical forming principle and the shaping trajectory, the applicable conditions and the interference judgment method are given and the composition of the machining error is analyzed.
The research results of the theory are applied to the manufacturing of helical surfaces within the PDM stator in technical applications. Some of the key technical problems are studied such as the guide and support of the slender milling rod, chip removal in the complex and deep hole, limited space transmission of the milling head and so on. A number of cutting tests are conducted and test results are analyzed to verify the theoretical studies mentioned above. Test result has proved, the theoretical research is feasible and correct.
The studies enrich and expand the theory and analytic tools to the helical surfaces, especially to the inner helicoid surfaces. It bings forward a new atypical cutting method using a certain size disc-milling cutter which provides new ideas and new approaches to improve the helical surface parts cutting efficiency in the field of innovating approaches. It has major significance for the development of the cutting machine tools which can manufacture parts with inner helicoid surface widely used in spiral mechanical parts manufacturing industry.
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