一种新型螺旋锥面刃磨理论及刃磨机床的研究
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摘要
钻削是生产过程中常用的加工方法,是金属切削加工中最重要的工序之一,约占所有金属切削加工工序的三分之一。合理地选择钻尖的几何形状和角度,可以很大程度地改善钻削性能,提高加工效率,而钻尖的几何形状和角度在很大程度上取决于所选择的后刀面刃磨方法,因此,许多学者一直致力于新钻型和新的刃磨方法的研究,作者在研究现有的锥面刃磨法和变导程螺旋面刃磨法的基础上,提出了一种新的刃磨法—螺旋锥面刃磨法。
本文首先在讨论研究锥面和变导程螺旋面刃磨原理和运动形式的基础上,确定了螺旋锥面刃磨法的运动形式,并在锥面和变导程螺旋面刃磨法数学模型的基础上,推导出了螺旋锥面钻头在钻尖坐标系中前刀面和后刀面的数学模型,以及机床坐标系中的刃磨方程,确定了螺旋锥面刃磨法的刃磨参数。
在确定了螺旋锥面刃磨法具体运动形式的基础上,在UG中绘制了一种螺旋锥面刃磨机的三维模型结构,并对其进行了运动仿真。在螺旋锥面刃磨法数学模型的基础上,推导出了刃磨参数与各个几何参数之间的关系,并利用Matlab绘制了刃磨参数对几何参数的影响曲线。
在对刃磨参数进行了特性分析后,固定了其中的一个参数,建立了刃磨参数和几何参数之间一一对应关系,并用Delphi软件建立螺旋锥面钻头的参数计算界面,从而确定了刃磨参数和几何参数之间的定量关系。对刃磨参数进行了敏感性分析,确定了刃磨参数对几何参数的影响程度大小,为刃磨机的结构和控制系统设计提供了依据。
利用UG软件建立了螺旋锥面钻头的三维模型,并对其进行了角度测量,验证了其能够得到更加合理的几何形状和后角分布；并利用Deform3D软件进行了螺旋锥面钻头钻削过程的有限元模拟,并把模拟结果与锥面钻头进行了比较,验证了其切削性能的优越性。
Drilling is one commonly-used processing method in the production process and one of most important procedures in metal-cutting process.approximately accounting for one-third of all metal-cutting processes.If the geometry and the angle of the drill point are reasonablely chosen,drilling performance will be improved and processing efficiency will be increased in a large extent, so, many scholars have been committed to the research on new drill point and new methods for grinding twist drill.On the basis of research on conical grinding method and variable lead helicoids grinding method,the author puts forward a new method for grinding twist drill—helical cone grinding method.
First,the paper discusses the grinding principle and the movement form of the conical grinding method and variable lead helicoids grinding method,and proposes movement form of the helical cone grinding method.On the basis of mathematic model of conical grinding method and variable lead helicoids grinding method, the author derive the equations of rake face and flank face of the helical cone drill point in the drill point coordinate system and the grinding equation of the flank face in the machine coordinate system and determine the grinding parameters of helical cone grinding method.
On the basis of determining movement form of helical cone grinding, the three-dimensional model of the helical cone cutter grinding machine is drawn by using UG softwear and the kinematics simulation is done. The relationship between grinding parameters and geometric parameters based on the mathematic model and draw the curve of grinding parameters influencing on geometric parameters is derived by using matalab.
After analyzing the character of grinding parameters, one of grinding parameters is fixed and one-to-one correspondence between grinding parameters and geometric parameters is defined.Otherwise, the interface for calculating parameters of helical cone drill point is established with Delphi softwear to determine quantitative relationship between grinding parameters and geometric parameters.After analyzing sensibility of grinding parameters, how great grinding parameters impact on geometric parameters is identified to provide a basis for manufacture of structure and control system of cutter grinding machine.
The three-dimensional model of helical cone drill point is established and its angels are measured proving that its back angel and its geometry are reasonable.Drilling process of helical cone drill point is simulated by using FEM analysis softwear Deform3D,comparing the result with cone drill point's to prove the machinability of helical cone drill point is better than cone drill point's.
本文首先在讨论研究锥面和变导程螺旋面刃磨原理和运动形式的基础上,确定了螺旋锥面刃磨法的运动形式,并在锥面和变导程螺旋面刃磨法数学模型的基础上,推导出了螺旋锥面钻头在钻尖坐标系中前刀面和后刀面的数学模型,以及机床坐标系中的刃磨方程,确定了螺旋锥面刃磨法的刃磨参数。
在确定了螺旋锥面刃磨法具体运动形式的基础上,在UG中绘制了一种螺旋锥面刃磨机的三维模型结构,并对其进行了运动仿真。在螺旋锥面刃磨法数学模型的基础上,推导出了刃磨参数与各个几何参数之间的关系,并利用Matlab绘制了刃磨参数对几何参数的影响曲线。
在对刃磨参数进行了特性分析后,固定了其中的一个参数,建立了刃磨参数和几何参数之间一一对应关系,并用Delphi软件建立螺旋锥面钻头的参数计算界面,从而确定了刃磨参数和几何参数之间的定量关系。对刃磨参数进行了敏感性分析,确定了刃磨参数对几何参数的影响程度大小,为刃磨机的结构和控制系统设计提供了依据。
利用UG软件建立了螺旋锥面钻头的三维模型,并对其进行了角度测量,验证了其能够得到更加合理的几何形状和后角分布；并利用Deform3D软件进行了螺旋锥面钻头钻削过程的有限元模拟,并把模拟结果与锥面钻头进行了比较,验证了其切削性能的优越性。
Drilling is one commonly-used processing method in the production process and one of most important procedures in metal-cutting process.approximately accounting for one-third of all metal-cutting processes.If the geometry and the angle of the drill point are reasonablely chosen,drilling performance will be improved and processing efficiency will be increased in a large extent, so, many scholars have been committed to the research on new drill point and new methods for grinding twist drill.On the basis of research on conical grinding method and variable lead helicoids grinding method,the author puts forward a new method for grinding twist drill—helical cone grinding method.
First,the paper discusses the grinding principle and the movement form of the conical grinding method and variable lead helicoids grinding method,and proposes movement form of the helical cone grinding method.On the basis of mathematic model of conical grinding method and variable lead helicoids grinding method, the author derive the equations of rake face and flank face of the helical cone drill point in the drill point coordinate system and the grinding equation of the flank face in the machine coordinate system and determine the grinding parameters of helical cone grinding method.
On the basis of determining movement form of helical cone grinding, the three-dimensional model of the helical cone cutter grinding machine is drawn by using UG softwear and the kinematics simulation is done. The relationship between grinding parameters and geometric parameters based on the mathematic model and draw the curve of grinding parameters influencing on geometric parameters is derived by using matalab.
After analyzing the character of grinding parameters, one of grinding parameters is fixed and one-to-one correspondence between grinding parameters and geometric parameters is defined.Otherwise, the interface for calculating parameters of helical cone drill point is established with Delphi softwear to determine quantitative relationship between grinding parameters and geometric parameters.After analyzing sensibility of grinding parameters, how great grinding parameters impact on geometric parameters is identified to provide a basis for manufacture of structure and control system of cutter grinding machine.
The three-dimensional model of helical cone drill point is established and its angels are measured proving that its back angel and its geometry are reasonable.Drilling process of helical cone drill point is simulated by using FEM analysis softwear Deform3D,comparing the result with cone drill point's to prove the machinability of helical cone drill point is better than cone drill point's.
引文
1.郭延文,黄祯祥.不同的刃磨方法对钻头性能影响的分析[J],工具技术,2007
2.倪志福,陈壁光.群钻[M],上海：上海科学技术出版社,1999,7-8.
3.熊梁山,师汉民,陈永洁.钻头与钻削研究的历史、现状与发展趋势[J],工具技术,2005
4.王忠魁等.麻花钻锥面刃磨翘尾现象的研究[J].陕西工学院学报,1998,14(2)：2-6
5.曹正铨等.钻尖的数学模型与钻削实验研究[M].北京理工大学出版社,1993,1-3
6.谢大纲.高效钻削机理的研究及新型钻头专用刃磨机的研制[D],哈尔滨工业大学,1999
7.李昌琪.工具和刀具磨床的新发展[M],上海：上海科学技术出版社,2002
8.张普礼,刘惠.麻花钻锥面磨削方法数学模型的建立[J],机电工程技术,2004
9.严兴春.麻花钻刃磨新方法—变导程螺旋面刃磨法[J],工具技术,2000
10.傅蔡安,时林,郑小虎,麻花钻后刀面螺旋锥面刃磨法的研究[J],工具技术,2007
11.周志雄.一种新型钻尖及其刃磨技术的研究[D],湖南大学,2001
12.林丞,曹正铨.群钻数学模型及其刃磨参数计算[J],工具技术,1990
13.郭延文.麻花钻刃磨方法的改进[J],机械工程师,2003
14.罗霞玉.新型钻头的几何特性分析及实验研究[D],湖南大学,2001
15.王群,李国锋等.UG零件设计实例与技巧[M],国防工业出版社,2005
16.孙亮.现代数控工具磨床S20turbo[J],制造技术与机床,第3期,2003
17.樊锐.钻尖刃磨机驱动及数控系统的研究[D],北京航空航天大学,1996,1-2
18.胡小康,徐六飞等.UG NX4运动分析培训教程[M],清华大学出版社,2006
19.邹平,杨旭磊.几种螺旋面钻尖刃磨机床的研制[J],制造技术与机床,第7期,2004
20.江洪道.虚轴数控钻尖刃磨机刃磨技术研究[D],北京航天航空大学,1999
21.邹平.CNC-6DGB数控钻尖刃磨机及钻尖刃磨技术的研究[D],北京航空航天大学,1997,1-2,28-30
22.林丞,曹正铨.锥面麻花钻补充几何参数的合理选择[J],湖南大学学报,1986,13(2),125-132
23.罗军辉,冯平等,MATALAB7.0在图像处理中的应用[M],机械工业出版社,2005
24.王家文,刘海等,MATALAB7.0编程基础[M],机械工业出版社,2005
25.徐进标,刘致仪Delphi5.0实例与编程入门[M],科学出版社,2000
26.薛定宇等.高等应用数学问题的MATLAB求解[M],清华大学出版社,2004,29-41.
27.李峰,聂文惠.Delphi5.0实用例库与高级编程技巧[M],人民邮电出版社,2000
28.周汝中.麻花钻钻尖刃磨参数的优化选择[J],水利电力机械,1997
29.王勇.麻花钻的重刃磨技术及计算机仿真[D],武汉理工大学,2002
30. Anish Paul S. G. Kapoor R. E. DeVor. A Chisel Edge Model for Arbitrary Drill Point Geometry [J],Department of Machanical and Industrial Engineering,2002
31. C.Lin, S.K.Kang, Kornel.F.Ehmann. Planar micro-drill point design and grinding methods [J], Transactions of NAMRI/SME,1992:173-179
32.时林等.基于UG的标准麻花钻三维实体建模及其角度测量[J],现代制造工程,2005
33.刘世瑶,耿芬然.深孔麻花钻的端截形及螺旋面的加工[J],河北冶金,2002,27-31
34.郑小虎.麻花钻新型后刀面刃磨方法的研究[D],江南大学,2008
35.张维纪.金属切削原理及刀具[M],浙江大学出版社,1991,120-128
36.王磊等.标准麻花钻三维实体模型的建立[J],工具技术,2007
37.杨军,周立平等.基于Deform3D的钻削力仿真研究[J],工具技术,2007
38.李传民,王向丽等.DEFORM5.03金属成型有限元分析实例指导教程[M],机械工业出版社,2007
39.黄志刚,柯映林等.金属切削加工有限元模拟的相关技术研究[J],中国机械工程,2003
40.杜云芝.钻削过程的塑性有限元数值模拟[D],天津大学,2006
41. A.Velayudham, R.Krishnamurthy. Effect of point geometry and their influence on thrust and delamination in drilling of polymeric composites[J], Journal of Materials Processing Technology,20
42. H. Hocheng,C.C.Tsao. Effects of special drill bits on drilling-induced delamination of composite materials [J], International Journal of Machine Tools & Manufacture,2006,46.1403-1416
43. Tsai, W.D., Wu, S.M. International Journal Machine Tools Design and Research,1979, 95-108.
44.韩荣第,杨昌琪,吴健.麻花钻的数学建模及钻削过程的有限元分析[J],工具技术,2008
45.陈日曜.金属切削原理[M],北京：机械工业出版社,1998,7-11.
46. C.C.Tsao, H. Hocheng. Taguchi analysis of delamination associated with various drill bits in drilling of composite material[J],International Journal of Machine Tools &Manufacture,2004,44:1085-1090
47. Sedat Karabay. Analysis of drill dynamometer with octagonal ring type transducers for monitoring of cutting forces in drilling and allied process[J], Materials and Design,2005
48. Fujii, M. F. Devries, Wu. M. S. An Analysis of Drill Geometry for Optimum Design by Computer, Part Ⅰ, Drill Geometry Analysis [J], Trans of the ASME,1970
49. Lajczok M R. A study of some aspects of metal cutting by finite element method. Ph D diseartation. NC State University,1980.1-2
2.倪志福,陈壁光.群钻[M],上海：上海科学技术出版社,1999,7-8.
3.熊梁山,师汉民,陈永洁.钻头与钻削研究的历史、现状与发展趋势[J],工具技术,2005
4.王忠魁等.麻花钻锥面刃磨翘尾现象的研究[J].陕西工学院学报,1998,14(2)：2-6
5.曹正铨等.钻尖的数学模型与钻削实验研究[M].北京理工大学出版社,1993,1-3
6.谢大纲.高效钻削机理的研究及新型钻头专用刃磨机的研制[D],哈尔滨工业大学,1999
7.李昌琪.工具和刀具磨床的新发展[M],上海：上海科学技术出版社,2002
8.张普礼,刘惠.麻花钻锥面磨削方法数学模型的建立[J],机电工程技术,2004
9.严兴春.麻花钻刃磨新方法—变导程螺旋面刃磨法[J],工具技术,2000
10.傅蔡安,时林,郑小虎,麻花钻后刀面螺旋锥面刃磨法的研究[J],工具技术,2007
11.周志雄.一种新型钻尖及其刃磨技术的研究[D],湖南大学,2001
12.林丞,曹正铨.群钻数学模型及其刃磨参数计算[J],工具技术,1990
13.郭延文.麻花钻刃磨方法的改进[J],机械工程师,2003
14.罗霞玉.新型钻头的几何特性分析及实验研究[D],湖南大学,2001
15.王群,李国锋等.UG零件设计实例与技巧[M],国防工业出版社,2005
16.孙亮.现代数控工具磨床S20turbo[J],制造技术与机床,第3期,2003
17.樊锐.钻尖刃磨机驱动及数控系统的研究[D],北京航空航天大学,1996,1-2
18.胡小康,徐六飞等.UG NX4运动分析培训教程[M],清华大学出版社,2006
19.邹平,杨旭磊.几种螺旋面钻尖刃磨机床的研制[J],制造技术与机床,第7期,2004
20.江洪道.虚轴数控钻尖刃磨机刃磨技术研究[D],北京航天航空大学,1999
21.邹平.CNC-6DGB数控钻尖刃磨机及钻尖刃磨技术的研究[D],北京航空航天大学,1997,1-2,28-30
22.林丞,曹正铨.锥面麻花钻补充几何参数的合理选择[J],湖南大学学报,1986,13(2),125-132
23.罗军辉,冯平等,MATALAB7.0在图像处理中的应用[M],机械工业出版社,2005
24.王家文,刘海等,MATALAB7.0编程基础[M],机械工业出版社,2005
25.徐进标,刘致仪Delphi5.0实例与编程入门[M],科学出版社,2000
26.薛定宇等.高等应用数学问题的MATLAB求解[M],清华大学出版社,2004,29-41.
27.李峰,聂文惠.Delphi5.0实用例库与高级编程技巧[M],人民邮电出版社,2000
28.周汝中.麻花钻钻尖刃磨参数的优化选择[J],水利电力机械,1997
29.王勇.麻花钻的重刃磨技术及计算机仿真[D],武汉理工大学,2002
30. Anish Paul S. G. Kapoor R. E. DeVor. A Chisel Edge Model for Arbitrary Drill Point Geometry [J],Department of Machanical and Industrial Engineering,2002
31. C.Lin, S.K.Kang, Kornel.F.Ehmann. Planar micro-drill point design and grinding methods [J], Transactions of NAMRI/SME,1992:173-179
32.时林等.基于UG的标准麻花钻三维实体建模及其角度测量[J],现代制造工程,2005
33.刘世瑶,耿芬然.深孔麻花钻的端截形及螺旋面的加工[J],河北冶金,2002,27-31
34.郑小虎.麻花钻新型后刀面刃磨方法的研究[D],江南大学,2008
35.张维纪.金属切削原理及刀具[M],浙江大学出版社,1991,120-128
36.王磊等.标准麻花钻三维实体模型的建立[J],工具技术,2007
37.杨军,周立平等.基于Deform3D的钻削力仿真研究[J],工具技术,2007
38.李传民,王向丽等.DEFORM5.03金属成型有限元分析实例指导教程[M],机械工业出版社,2007
39.黄志刚,柯映林等.金属切削加工有限元模拟的相关技术研究[J],中国机械工程,2003
40.杜云芝.钻削过程的塑性有限元数值模拟[D],天津大学,2006
41. A.Velayudham, R.Krishnamurthy. Effect of point geometry and their influence on thrust and delamination in drilling of polymeric composites[J], Journal of Materials Processing Technology,20
42. H. Hocheng,C.C.Tsao. Effects of special drill bits on drilling-induced delamination of composite materials [J], International Journal of Machine Tools & Manufacture,2006,46.1403-1416
43. Tsai, W.D., Wu, S.M. International Journal Machine Tools Design and Research,1979, 95-108.
44.韩荣第,杨昌琪,吴健.麻花钻的数学建模及钻削过程的有限元分析[J],工具技术,2008
45.陈日曜.金属切削原理[M],北京：机械工业出版社,1998,7-11.
46. C.C.Tsao, H. Hocheng. Taguchi analysis of delamination associated with various drill bits in drilling of composite material[J],International Journal of Machine Tools &Manufacture,2004,44:1085-1090
47. Sedat Karabay. Analysis of drill dynamometer with octagonal ring type transducers for monitoring of cutting forces in drilling and allied process[J], Materials and Design,2005
48. Fujii, M. F. Devries, Wu. M. S. An Analysis of Drill Geometry for Optimum Design by Computer, Part Ⅰ, Drill Geometry Analysis [J], Trans of the ASME,1970
49. Lajczok M R. A study of some aspects of metal cutting by finite element method. Ph D diseartation. NC State University,1980.1-2