重型数控落地铣镗床结构热变形误差预测技术的研究
|
摘要
数控机床在加工的过程中,在各种热源:如轴承发热、电机发热、导轨发热及其它热源的作用下,会导致机床上的部件发生不同程度的热变形,在这些热变形的叠加作用下,导致机床刀尖处的位置精度遭到破坏,由此导致的误差称为热误差。据资料显示,数控机床在加工过程中由于热变形引起的加工误差占机床全部误差的40～70﹪。
重型数控机床用于加工特大型零件,在航天、航空等工业领域有着广泛的应用,其具有体积大、质量重、行程范围远等特点,由于各部件热变形导致的热误差不容忽视。本论文针对某型号重型数控落地铣镗床,对其热误差进行了分析并预测。论文主要进行如下研究工作:
阐述了传热学相关理论及有限元方法在其中的应用,并建立了机床的三维有限元模型。在对机床的热源和边界条件进行分析并计算后,对机床温度场和变形场进行了分析。
研究了温度传感器的优化选择方法。在机床上根据经验初步布置了温度传感器之后,进行热误差实验,采集温度和热误差数据。利用传感器的优化选择策略:主因素策略、互不相关策略、最大灵敏度策略,筛选出用于热误差建模的温度关键点。为了考虑不同策略对选取结果的影响,在最后一步中根据策略的不同出了两种方案。
研究了多元线性回归理论及其在热误差建模中的应用。针对上述两种方案,基于逐步回归法选取了回归变量并分别在X、Y、Z三个方向建立了热误差预测模型。分析并比较两种建模结果的预测精度后,得出最终的热误差建模方案。
During the process of machining, there are varieties of heat sources, such as the beating of bearing, the beating of motor and the beating of slide-way, they can lead to the thermal distortion the different structural elements. Under the action of superposition of various thermal distortions, the accuracy of the position of the tool is destroyed, as it is called thermal error. It has been shown that the thermal error of machine tool can account for 40～70 percents of the total machine error.
The heavy NC machine tools which are widely applied in the field of aerospace and others are usually used on machining of heavy parts, which has the characteristic of large volume, heavy mass and long range of travel, and its thermal errors that are caused by thermal deformation cannot be ignored. Aiming at some heavy type milling boring ma-chine tool, the machine tool thermal errors are analyzed and forecasted in this disserta-tion. The main research achievement of this dissertation is as follows:
The theory of heat transfer and the application of finite element is elaborated, and also the finite element model is modeled. After analyzing and calculating the heat and boundary conditions, this dissertation analyzed the temperature field and thermal defor-mation .
The method of optimization selection of temperature sensor is researched. After ar-ranging the temperature sensors by experience on the machine tool, the thermal error ex-periment is conducted. By the use of strategy of optimization selection of temperature sensor, such as principal factor, mutually uncorrelated and maximum sensitivity, the crit-ical temperature points that are used for thermal error modeling are selected in three pro-cedures. Considering the impact on the selecting result, two different proposals are raised according to the strategy in the last procedure.
The application of theory of the multiple linear regression on the thermal error mod-eling is analyzed. Aiming at the two proposals that are discussed, the regression variables are selected by stepwise weakening and the thermal error models are established in three directions. After analyzing and comparing the forecast precision of the results of the two models, the final thermal error model is recommended.
重型数控机床用于加工特大型零件,在航天、航空等工业领域有着广泛的应用,其具有体积大、质量重、行程范围远等特点,由于各部件热变形导致的热误差不容忽视。本论文针对某型号重型数控落地铣镗床,对其热误差进行了分析并预测。论文主要进行如下研究工作:
阐述了传热学相关理论及有限元方法在其中的应用,并建立了机床的三维有限元模型。在对机床的热源和边界条件进行分析并计算后,对机床温度场和变形场进行了分析。
研究了温度传感器的优化选择方法。在机床上根据经验初步布置了温度传感器之后,进行热误差实验,采集温度和热误差数据。利用传感器的优化选择策略:主因素策略、互不相关策略、最大灵敏度策略,筛选出用于热误差建模的温度关键点。为了考虑不同策略对选取结果的影响,在最后一步中根据策略的不同出了两种方案。
研究了多元线性回归理论及其在热误差建模中的应用。针对上述两种方案,基于逐步回归法选取了回归变量并分别在X、Y、Z三个方向建立了热误差预测模型。分析并比较两种建模结果的预测精度后,得出最终的热误差建模方案。
During the process of machining, there are varieties of heat sources, such as the beating of bearing, the beating of motor and the beating of slide-way, they can lead to the thermal distortion the different structural elements. Under the action of superposition of various thermal distortions, the accuracy of the position of the tool is destroyed, as it is called thermal error. It has been shown that the thermal error of machine tool can account for 40～70 percents of the total machine error.
The heavy NC machine tools which are widely applied in the field of aerospace and others are usually used on machining of heavy parts, which has the characteristic of large volume, heavy mass and long range of travel, and its thermal errors that are caused by thermal deformation cannot be ignored. Aiming at some heavy type milling boring ma-chine tool, the machine tool thermal errors are analyzed and forecasted in this disserta-tion. The main research achievement of this dissertation is as follows:
The theory of heat transfer and the application of finite element is elaborated, and also the finite element model is modeled. After analyzing and calculating the heat and boundary conditions, this dissertation analyzed the temperature field and thermal defor-mation .
The method of optimization selection of temperature sensor is researched. After ar-ranging the temperature sensors by experience on the machine tool, the thermal error ex-periment is conducted. By the use of strategy of optimization selection of temperature sensor, such as principal factor, mutually uncorrelated and maximum sensitivity, the crit-ical temperature points that are used for thermal error modeling are selected in three pro-cedures. Considering the impact on the selecting result, two different proposals are raised according to the strategy in the last procedure.
The application of theory of the multiple linear regression on the thermal error mod-eling is analyzed. Aiming at the two proposals that are discussed, the regression variables are selected by stepwise weakening and the thermal error models are established in three directions. After analyzing and comparing the forecast precision of the results of the two models, the final thermal error model is recommended.
引文
1 Bryan J B. International Status of Thermal Error Research. Annals of CIRP. 1990, 39 (2): 645-656
2 Ferreira PM. Liu C R. A Method for Estimating and Compensating Quasistatic Er-rors of Machine Tools. Journal of Engineering for Industry. 1993,115 (1): 149-159
3 Robert B Aronson. War against Thermal Expansion. Manufacturing Engineering. 1996, 116 (6): 45-50
4倪军.数控机床误差补偿研究的回顾及展望.中国机械工程. 1997,8(1): 29-33
5 Camera A, Favarato M, Mililani L, et al. Analysis of the Thermal Behavior of a Machine Tool Table Using the Finite Element Method. Annals of CIRP. 1976, 25(1): 58-64
6 Spur G, Hoffmann E, Paluncic Z, et al. Thermal Behavior Optimization of Machine Tools. Annals of CIRP. 1988, 37(1): 31-33
7 M. Sharif Uddin, Soichi Ibaraki, et al. Prediction and Compensation of Machining-geometric of Five-axis Maching Centers with Kinematic Errors. Precision Engineer-ing. 2009,33: 194-201
8 Schafer W.机床的热变形补偿. Ind.-Anz.1990,112(72)
9千辉淳二.机床温度控制研究(VI).精密工学杂志. 1990.56(7)[日]
10 Yourdon David H.车床温度测量装置. US4998957[专,英], 1993.3
11松尾光荣.通过对加工中心的温度分布测量进行热位移补偿(II).精密工学杂志. 1991,57(3)[日]
12 J.S.Chen, J.X.Yuan, S.M.Wu. Real-time Compensation for Time-variant Volumetric Errors on a Machining Centre. ASME TransJournal of Engineering for Industry. 1993,4(115): 472–479
13 S.C.Veldhuis, M.A.Elbestawi. A Strategy for Compensation of Errors in Five-Axis Machining. Annals of CIRP. 1995,44(1): 373-377.
14 J.Lee, B.M.Kramer. Analysis of Machine Degradation Using a Neural Network Based Pattern Discrimination Mode. Journal of Manufacturing Systems. 1993, 38(2): 379-387
15西村真桢.应用模糊理论抑制主轴的热变形.机械的工具. 1993,37(2)[日]
16 Fraser.S, M.H.Attia, M.O.M.Osman. Modeling, Identification and Control of Thermal Deformation of Machine Tool Structures, Part I: Concept of Generalized Modeling. ASME Journal of Manufacturing Science and Engineering. 1998, 120(3): 623-631
17 J.Jedrzejewski, J.Kaczmarek, Z.Kowal,Z. Winiarski. Numerical Optimization of Thermal Behavior of Machine Tools. Annals of the CIRP. 1990,39(1): 379-382
18 Lo.C, J.Yuan, Jun. Ni. Optimal Temperature Variable Selection by Grouping Ap-proach for Thermal Error Modeling and Compensation. International Journal of Ma-chineTools and Manufacture. 1999,39(9): 1383-1396
19 Yi ding Wang, Guoxiong Zhang, Kee S.Moon, John W.Sutherland. Compensation for the Thermal Error of a Multi-axis Machining center. Journal of Material Processing Technology. 1998, 7: 545-53
20 R.Ramesh, M.A.Mannan, A.N.Poo. Thermal Error Measurement and Modeling in Machine Tools. PartⅠ.Influence of Varying Operating Conditions. International Journal of Machine Tools&Manufacture. 2003,43: 391-404
21 Hong Yang, Jun Ni. Adaptive Model Estimation of Machine Tool Thermal errors Based on Recursive Dynamic Modeling Strategy. International Journal of Machine Tools&Manufacture. 2005, 45: 1-11
22 F.L.M, Delbressine, G.H.J.Florussen, L.A.Schijvenaars, P.H.J.Schellekens. Model-ling Thermomechanical Behaviour of Multi-axis Machine Tools. Precision Engi-neering. 2006, 30: 47-53
23 Yuan Kang, Chun-wei Chang, Yuanruey Huang, Chuag-Liang Hsu, I-Fu Nieh. Mod-ification of a Neural Network Utilizing Hybrid Filters for the Compensation of Thermal Deformation in Machine Tools. International Journal of Machine Tools &Manufacture. 2007, 473: 376-387
24陈子辰,等.热敏感度和热耦合度研究. 1992年全国机床热误差控制和补偿研究会议论文集. 1992,5: 49-53
25金键,甘锡英.机床主轴温升和热变形在线检测及显示系统.机械与电子. 1993,3: 3-4
26张德贤,刘筱连,师汉民等.神经网络在数控机床热变形控制中的应用.制造技术与机床. 1995,1: 8-11
27 R.Venugopal, M.Barash. Thermal Effects on the Accuracy of Numerically Controlled Machine tools. Annals of the CIRP. 1986,35: 255-258
28杨建国,任永强,朱卫斌,黄明礼,潘志宏.数控机床热误差补偿模型在线修正方法研究.机床工程学报. 2003,2(5): 58-61
29于金.数控机床热误差的模型预报补偿.组合机床与自动化加工技术. 2002,35(4):7-8
30于金,赵树国,赵益华.机床热误差的无限冲激响应网络动态模型.沈阳航空工业学院学报. 2002,3(5): 33-35
31洪有为.机床主轴系统热特性建模分析及结构优化设计.东南大学硕士学位论文. 2005
32杨世铭.传热学[M]:第二版.北京:高等教育出版社, 1992
33黎新奇.铣削加工中心主轴组件热特性的研究.兰州理工大学硕士论文. 2008
34叶艳,刘强,袁松梅等.龙门加工中心主轴系统热特性的有限元分析.机床设计研究. 2007,(2): 32-35
35赵海涛.数控机床热误差模态分析、测点布置及建模研究.上海交通大学博士学位论文.2006
36徐文琴,孙英达.机床液体静压导轨油膜厚度确定的研究.制造技术与机床. 2009, 6: 36-37
37郭策,孙庆鸿等.高速高精度数控车床主轴系统的温度场建模与仿真.制造业自动化. 2003, 25(2): 17-19
38张耀满,高冠滨等.加工中心主轴组件及其主轴箱的热特性有限元分析.组合机床与自动化加工技术. 2005,5: 43-52
39 J.G. Yang, H.T. Zhao et al. Testing, Variable Selecting and Modeling of Thermal Er-rors on an INDEX-G200 Turning Center. International Journal of Machine Tools and Manufacture. 2005(26): 814-818
40 Chih-Hao Lo, Jingxia Yuan,Jun Ni. Optimal Temperature Variable Selection by Grouping Approach for Thermal Error Modeling and Compensation. 1999(39): 1383-1396
41欧阳健飞,刘万里,闫永刚,梁智勇.激光跟踪仪坐标测量精度的研究.红外与激光工程. 2008, 37(4): 15-18
42 M.Weck, RWTH Aachen. Reduction and Compensation of Thermal Errors in Ma-chine Tools. International Journal of Machine Tools and Manufacture. 1995(5): 593-597
43郭前建,杨建国,李永祥等.聚类回归分析在滚齿机热误差建模中的应用.上海交通大学学报. 2008, 42(7): 1055-1059
44王智明,彭安华,王其兵.多项式回归理论在机床热误差建模中的应用.兰州理工大学学报. 2007,33(6):40-42
45 Jenq-Shyong Chen. A Study of Thermally Induced Machine Tool Errors in Real Cut ting Conditions. International Journal of Machine Tools& Manufacture ting Condi tions. International Journal of Machine Tools& Manufacture. 1996,36(12): 1401- 1411
46严乐,卢秉恒,丁玉成,刘红忠.高精度步进压印机热误差的建模分析.西安交通大学学报. 2005,39: 525-53
47 Hong Yang. Dynamic Modeling for Machine Tool Thermal Error Compensation. Ph.D.Thesis. The University of Michigan. 2002
48 Seber, G.A.F. Linear Regression Analysis. John Wiley& sons, 1990
49何晓群,刘文卿.应用回归分析(第二版).中国人民大学出版社, 2007
50柳金甫,于义良.应用数理统计.清华大学出版社, 2008
51李小力,周云飞,李作青,周济.数控机床热敏感点识别研究.计算技术与自动化. 1998,7: 54-56
2 Ferreira PM. Liu C R. A Method for Estimating and Compensating Quasistatic Er-rors of Machine Tools. Journal of Engineering for Industry. 1993,115 (1): 149-159
3 Robert B Aronson. War against Thermal Expansion. Manufacturing Engineering. 1996, 116 (6): 45-50
4倪军.数控机床误差补偿研究的回顾及展望.中国机械工程. 1997,8(1): 29-33
5 Camera A, Favarato M, Mililani L, et al. Analysis of the Thermal Behavior of a Machine Tool Table Using the Finite Element Method. Annals of CIRP. 1976, 25(1): 58-64
6 Spur G, Hoffmann E, Paluncic Z, et al. Thermal Behavior Optimization of Machine Tools. Annals of CIRP. 1988, 37(1): 31-33
7 M. Sharif Uddin, Soichi Ibaraki, et al. Prediction and Compensation of Machining-geometric of Five-axis Maching Centers with Kinematic Errors. Precision Engineer-ing. 2009,33: 194-201
8 Schafer W.机床的热变形补偿. Ind.-Anz.1990,112(72)
9千辉淳二.机床温度控制研究(VI).精密工学杂志. 1990.56(7)[日]
10 Yourdon David H.车床温度测量装置. US4998957[专,英], 1993.3
11松尾光荣.通过对加工中心的温度分布测量进行热位移补偿(II).精密工学杂志. 1991,57(3)[日]
12 J.S.Chen, J.X.Yuan, S.M.Wu. Real-time Compensation for Time-variant Volumetric Errors on a Machining Centre. ASME TransJournal of Engineering for Industry. 1993,4(115): 472–479
13 S.C.Veldhuis, M.A.Elbestawi. A Strategy for Compensation of Errors in Five-Axis Machining. Annals of CIRP. 1995,44(1): 373-377.
14 J.Lee, B.M.Kramer. Analysis of Machine Degradation Using a Neural Network Based Pattern Discrimination Mode. Journal of Manufacturing Systems. 1993, 38(2): 379-387
15西村真桢.应用模糊理论抑制主轴的热变形.机械的工具. 1993,37(2)[日]
16 Fraser.S, M.H.Attia, M.O.M.Osman. Modeling, Identification and Control of Thermal Deformation of Machine Tool Structures, Part I: Concept of Generalized Modeling. ASME Journal of Manufacturing Science and Engineering. 1998, 120(3): 623-631
17 J.Jedrzejewski, J.Kaczmarek, Z.Kowal,Z. Winiarski. Numerical Optimization of Thermal Behavior of Machine Tools. Annals of the CIRP. 1990,39(1): 379-382
18 Lo.C, J.Yuan, Jun. Ni. Optimal Temperature Variable Selection by Grouping Ap-proach for Thermal Error Modeling and Compensation. International Journal of Ma-chineTools and Manufacture. 1999,39(9): 1383-1396
19 Yi ding Wang, Guoxiong Zhang, Kee S.Moon, John W.Sutherland. Compensation for the Thermal Error of a Multi-axis Machining center. Journal of Material Processing Technology. 1998, 7: 545-53
20 R.Ramesh, M.A.Mannan, A.N.Poo. Thermal Error Measurement and Modeling in Machine Tools. PartⅠ.Influence of Varying Operating Conditions. International Journal of Machine Tools&Manufacture. 2003,43: 391-404
21 Hong Yang, Jun Ni. Adaptive Model Estimation of Machine Tool Thermal errors Based on Recursive Dynamic Modeling Strategy. International Journal of Machine Tools&Manufacture. 2005, 45: 1-11
22 F.L.M, Delbressine, G.H.J.Florussen, L.A.Schijvenaars, P.H.J.Schellekens. Model-ling Thermomechanical Behaviour of Multi-axis Machine Tools. Precision Engi-neering. 2006, 30: 47-53
23 Yuan Kang, Chun-wei Chang, Yuanruey Huang, Chuag-Liang Hsu, I-Fu Nieh. Mod-ification of a Neural Network Utilizing Hybrid Filters for the Compensation of Thermal Deformation in Machine Tools. International Journal of Machine Tools &Manufacture. 2007, 473: 376-387
24陈子辰,等.热敏感度和热耦合度研究. 1992年全国机床热误差控制和补偿研究会议论文集. 1992,5: 49-53
25金键,甘锡英.机床主轴温升和热变形在线检测及显示系统.机械与电子. 1993,3: 3-4
26张德贤,刘筱连,师汉民等.神经网络在数控机床热变形控制中的应用.制造技术与机床. 1995,1: 8-11
27 R.Venugopal, M.Barash. Thermal Effects on the Accuracy of Numerically Controlled Machine tools. Annals of the CIRP. 1986,35: 255-258
28杨建国,任永强,朱卫斌,黄明礼,潘志宏.数控机床热误差补偿模型在线修正方法研究.机床工程学报. 2003,2(5): 58-61
29于金.数控机床热误差的模型预报补偿.组合机床与自动化加工技术. 2002,35(4):7-8
30于金,赵树国,赵益华.机床热误差的无限冲激响应网络动态模型.沈阳航空工业学院学报. 2002,3(5): 33-35
31洪有为.机床主轴系统热特性建模分析及结构优化设计.东南大学硕士学位论文. 2005
32杨世铭.传热学[M]:第二版.北京:高等教育出版社, 1992
33黎新奇.铣削加工中心主轴组件热特性的研究.兰州理工大学硕士论文. 2008
34叶艳,刘强,袁松梅等.龙门加工中心主轴系统热特性的有限元分析.机床设计研究. 2007,(2): 32-35
35赵海涛.数控机床热误差模态分析、测点布置及建模研究.上海交通大学博士学位论文.2006
36徐文琴,孙英达.机床液体静压导轨油膜厚度确定的研究.制造技术与机床. 2009, 6: 36-37
37郭策,孙庆鸿等.高速高精度数控车床主轴系统的温度场建模与仿真.制造业自动化. 2003, 25(2): 17-19
38张耀满,高冠滨等.加工中心主轴组件及其主轴箱的热特性有限元分析.组合机床与自动化加工技术. 2005,5: 43-52
39 J.G. Yang, H.T. Zhao et al. Testing, Variable Selecting and Modeling of Thermal Er-rors on an INDEX-G200 Turning Center. International Journal of Machine Tools and Manufacture. 2005(26): 814-818
40 Chih-Hao Lo, Jingxia Yuan,Jun Ni. Optimal Temperature Variable Selection by Grouping Approach for Thermal Error Modeling and Compensation. 1999(39): 1383-1396
41欧阳健飞,刘万里,闫永刚,梁智勇.激光跟踪仪坐标测量精度的研究.红外与激光工程. 2008, 37(4): 15-18
42 M.Weck, RWTH Aachen. Reduction and Compensation of Thermal Errors in Ma-chine Tools. International Journal of Machine Tools and Manufacture. 1995(5): 593-597
43郭前建,杨建国,李永祥等.聚类回归分析在滚齿机热误差建模中的应用.上海交通大学学报. 2008, 42(7): 1055-1059
44王智明,彭安华,王其兵.多项式回归理论在机床热误差建模中的应用.兰州理工大学学报. 2007,33(6):40-42
45 Jenq-Shyong Chen. A Study of Thermally Induced Machine Tool Errors in Real Cut ting Conditions. International Journal of Machine Tools& Manufacture ting Condi tions. International Journal of Machine Tools& Manufacture. 1996,36(12): 1401- 1411
46严乐,卢秉恒,丁玉成,刘红忠.高精度步进压印机热误差的建模分析.西安交通大学学报. 2005,39: 525-53
47 Hong Yang. Dynamic Modeling for Machine Tool Thermal Error Compensation. Ph.D.Thesis. The University of Michigan. 2002
48 Seber, G.A.F. Linear Regression Analysis. John Wiley& sons, 1990
49何晓群,刘文卿.应用回归分析(第二版).中国人民大学出版社, 2007
50柳金甫,于义良.应用数理统计.清华大学出版社, 2008
51李小力,周云飞,李作青,周济.数控机床热敏感点识别研究.计算技术与自动化. 1998,7: 54-56