切削力测量仪的开发
摘要
随着切削加工向着高速、高精度、高度自动化方向发展,对切削过程的监控技术也提出了越来越高的要求,而各种自动化机械加工设备与制造系统绝大多数并不具备加工过程的监控功能。为了使这些高度自动化加工设备充分发挥其优良性能,确保加工质量,提高生产效率,对刀具加工过程进行状态监测与控制就越来越重要。大量的研究结果表明,切削状态的每个微小变化都能通过切削力的变化反映出来。检测切削力是目前国内外研究与应用最多的监测方法之一,但这些方法在使用时或多或少地要改变机床的原有部件,影响机床的系统特性,并且在机械加工过程中,车削测力仪的应用最为广泛。针对这些问题,需要设计出一种外型尺寸和使用状态都类似于普通外圆车刀的车削测力仪。
本文详细论述了车削力测量仪的总体设计过程,主要包括测力仪的外型整体结构设计、压电传感器的设计、软件部分的设计和外围设备的选用。该车削力测量仪与原有车削测力仪相比的突出特点是:它的外形接近一把普通的外圆车刀,可直接装夹在刀架上,与实际切削状态相同,能够实时显示切削过程中切削力的变化;通过理论计算分析,得出传感器的灵敏度、固有频率以及其它技术指标可以达到CERP—STCC规定的测力仪标准;而且结构简捷、调试方便、成本较低,不但适用于实验室,并且将适用于实际生产的测试与实时监控中。
According as cutting process is developing to high speed, high precision and high automatization, more and more higher request was put forward for monitor of cutting process, but most kinds of automatization equipment manufacture system could not monitor. In order to exert good performance of high automatization equipment, ensure machining quality and improve manufacture efficiency, it is more important to monitor and control for state of tool machining process. A lot of investigations indicate that every small change of cutting state could be reflected via the change of cutting force. Measuring cutting force is one of the most common methods in domestic and external investigation. But parts of machine tool would be changed more or less using this measure, which would influence the characteristics of system, and in the course of machining, cutting dynamometer is most widely used. For these problems, a new type of cutting dynamometer should be designed, whose structure size and state of using are similar to general lathe tool.
This thesis is focused on the course of designing the dynamometer on cutting force, which mainly includes the appearance overall structural design of dynamometer, the design of piezoelectric sensors, the software part of the design and the peripheral equipment selection. Compared with the originally possessed dynamometer sensor, it has several outstanding features as following: more similar to general lathe tool, could be installed on knife rest, same wit practice state of cutting and it is real-time display of the cutting process of cutting force changes; Through theoretical calculation and analysis, the sensitivity and natural frequency of the cutting dynamometer has reached the dynamometer standard stipulated by CERP-STCC. And the structure is simple, convenient for checkout and its production cost is low. So it could be used not only in laboratory but also in testing of practical production and real-time control.
本文详细论述了车削力测量仪的总体设计过程,主要包括测力仪的外型整体结构设计、压电传感器的设计、软件部分的设计和外围设备的选用。该车削力测量仪与原有车削测力仪相比的突出特点是:它的外形接近一把普通的外圆车刀,可直接装夹在刀架上,与实际切削状态相同,能够实时显示切削过程中切削力的变化;通过理论计算分析,得出传感器的灵敏度、固有频率以及其它技术指标可以达到CERP—STCC规定的测力仪标准;而且结构简捷、调试方便、成本较低,不但适用于实验室,并且将适用于实际生产的测试与实时监控中。
According as cutting process is developing to high speed, high precision and high automatization, more and more higher request was put forward for monitor of cutting process, but most kinds of automatization equipment manufacture system could not monitor. In order to exert good performance of high automatization equipment, ensure machining quality and improve manufacture efficiency, it is more important to monitor and control for state of tool machining process. A lot of investigations indicate that every small change of cutting state could be reflected via the change of cutting force. Measuring cutting force is one of the most common methods in domestic and external investigation. But parts of machine tool would be changed more or less using this measure, which would influence the characteristics of system, and in the course of machining, cutting dynamometer is most widely used. For these problems, a new type of cutting dynamometer should be designed, whose structure size and state of using are similar to general lathe tool.
This thesis is focused on the course of designing the dynamometer on cutting force, which mainly includes the appearance overall structural design of dynamometer, the design of piezoelectric sensors, the software part of the design and the peripheral equipment selection. Compared with the originally possessed dynamometer sensor, it has several outstanding features as following: more similar to general lathe tool, could be installed on knife rest, same wit practice state of cutting and it is real-time display of the cutting process of cutting force changes; Through theoretical calculation and analysis, the sensitivity and natural frequency of the cutting dynamometer has reached the dynamometer standard stipulated by CERP-STCC. And the structure is simple, convenient for checkout and its production cost is low. So it could be used not only in laboratory but also in testing of practical production and real-time control.
引文
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[2]W.P.Mason.Piezoelectricity,its history and applications[J].Acoustical Society of America,1981,70(6):1561-1566.
[3]李远,秦自楷.压电和铁电材料的测量[M].第一版,北京:科学出版社,1984.
[4]刘光聪.压电陶瓷材料的新近走势[J].世界产品与技术,2001,122(26):41-43.
[5]J.Nowotny.Electronic Ceramic Materials[M].Switzerland:Tans Tech Publications,1992.
[6]孙宝元,张贻恭.压电石英力传感器及动态切削测力仪[M].第一版,北京:计量出版社,1985.
[7][日]森林正直,山歧弘郎著,孙宝元译.传感工程学[M].第一版,大连:大连工学院出版社,1988.
[8]陈长青,田晓耕,沈亚鹏.压电介质有限变形的增量变分方程[J].固体力学学报,1998,19(3):228-238.
[9]钱敏,孙宝元.压电测力平台中传感器新的配置原则[C].第四届全国敏感元件与传感器学术会议,1995,5.
[10]孙宝元,王吉军,钱敏.压电石英晶片灵敏度分布规律及其跟踪检测[J].大连理工大学学报,1990,30(1):59-64.
[11]孙宝元,张贻恭,杨华敏.压电式动态切削测力仪(上、下)[M].机床,1979,5.
[1 2]刘培德,胡荣生,孙宝元.切削力学新篇(学术专著)[M].第一版,大连:大连理工大学出版社,1991.
[13]张贻恭,孙宝元.YDS-Ⅲ79B,YDS-Ⅲ79K型石英晶体三维力传感器的设计与研制[J].大连工学院学报,1981,20(1):1-9.
[14]秦自楷.压电石英晶体[M].第一版,北京:国防工业出版社,1980.
[15]孙宝元,杨宝清.传感器及其应用手册第一版[M].北京机械工业出版社,2004.
[16]刘晓东.应变式切削测力系统动态特性的研究[J].工业仪表与自动化装置,1999(5):3-7.
[17]唐偃生,韩永澎.GH-Ⅱ实体压磁式测力仪的研制与应用[J].工业计量,2002(5):41-42.
[18]陈纲,廖理几.晶体物理学基础[M].北京科学出版社,1992.
[19]闫西林,远永丰,吴顺华等.晶体物理学[M].北京:电子工业出版社,1995.
[20]韩丽丽.无定心钻削测力仪的结构优化设计[D].大连:大连理工大学,2005.
[21]孙宝元,张弘涛.三向压电车削测力仪[C].北京国际生产工程学会暨生产工程学会第五届大会,1988,9.
[22]洪水棕.现代测试技术[M].上海:上海交通大学出版社,2002.
[23]彭军.传感器与检测技术[M].西安:西安电子科举大学出版社,2003.
[24]施文济.自动系统中的测量与显示技术[M].北京:中国水利水电出版社,2003.
[25]Ad link Technology INC.NuDAQ ACL-8111 User's Guide,2001.
[26]刘晓玲.新型压电动态切削测力仪的结构设计与优化分析[D].大连:大连理工大学,2005.
[27]孙宝元.三向压电式车削测力仪结构优化设计[J].机械工程学报,NO.3,1990.
[28]孙宝元,牛志明,韩庚林,钱敏.三维组合压阻式低频加速度传感器的研制与标定[J].大连理工大学学报,NO.5,1992;STC'91第二届全国敏感元件与传感器学术会议论文集,1991,11.
[29]张福学.现代压电学[M].第一版,北京:科学出版社,2002.
[30]刘齐茂,李微.传感器弹性元件的结构优化设计[J].仪表技术与传感器,2004(6):6-9.
[31]孙宝元,钱敏,张军.一种新型径向测力轴承传感器的研制[C].第四届全国敏感元件与传感器学术会议论文集,上海,1995,5.
[32]孙宝元,钱敏,张军.压电式传感器与测力仪研发回顾与展望[J].大连理工大学学报,2001,41(2):127-134.
[33]张华.ALGOB FEAS软件在塔机结构计算中的应用[J].建筑机械,1996(10):22-24.
[34]孙宝元.测力轴承在切削监控中的应用与发展[C].第四届全国敏感元件与传感器学术会议论文集,上海,1995,5.
[35]虞永超,孙宝元.轮辐式三维加速度传感器弹性元件优化设计[J].大连理工大学学报,NO.5,1995,10.
[36]孙宝元,张贻恭,王子江.一种简便实用的压电石英晶体刀杆式三向车削测力仪[J].大连工学院学报,1983,21(2):85-94.
[37]Luis Ricardo Castro,Pascal vieville and Paul Lipinski.Correction of dynamic effects on force measurements made with piezoelectric dynamometers[J].International Journal of Machine Tools & Manufacture,2006(46):1707-1715.
[38]Dong feng shi and Nabil N.Gindy.Development of an online machining process monitoring system:Application in hard turning[J].Sensors and Actuators A PHYSICAL,2006(10):1-5.
[39]Saulius Kausinis and Rimantas Barauskas.Computer simulation of a piezoelectric angular rate sensor[J].Measurement,2006(39):947-958.
[40]A.Pramanik,L.C.Zhang and J.A.Arsecularatne.Prediction of cutting forces in machining of metal matrix composites[J].International Journal of Machine Tools &Manufacture,2006(46):1795-1803.
[41]P.G.Benardos,S.Mosialos and G.-C.Vosniakos.Prediction of workpiece elastic deflections under cutting forces in turning[J].Robotics and Computer-Integrated Manufacturing,2006(22):505-514.
[42]Martin Baker.Finite element simulation of high-speed cutting forces[J].Journal of Materials Processing Technology,2006(176):117-126.
[43]J.Grum and M.Kisin.The influence of the microstructure of three Al-Si alloys on the cutting-force amplitude during fine turning[J].International Journal of Machine Tools & Manufacture,2006(46):769-781.
[44]Sedat Karabay.Design criteria for electro-mechanical transducers and arrangement for measurement of strains due to metal cutting forces acting on dynamometers[J].Materials and Design,2006(28):496-506.
[45]M F Aly,E.Ng,S.C.Veldhuis,etal.Prediction of cutting forces in the micro-machining of silicon using a "hybrid molecular dynamic-finite element analysis" force model[J].International Journal of Machine Tools & Manufacture,2006(46):1727-1739.
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