摆线旋分加工技术的研究与实践
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摘要
目前摆线旋分加工机床的专用性较强,不利于推广。为了使其具有通用性,本文通过原理分析与加工试验对摆线旋分加工方法做了大量的研究。论文首先从摆线发生的数学模型出发,给出了摆线的定义和参数方程,并阐述了摆线旋分加工原理。通过分析摆线各参数对摆线形状的影响,根据被加工零件的表面特征,将零件分为三类,即偶多边形及端面槽类、奇多边形类和渐开线类。在此基础上针对各类零件建立通用模型,在保证一定的逼近精度的前提下,以加工效率最高为目标,设计摆线参数优化算法。然后,根据优化的摆线参数,编制相应的数控程序进行实切验证。通过大量工艺试验,总结摆线旋分加工法的工艺特点以及刀具材料的选择方法,找出影响加工精度的主要因素,如刀具制造安装误差、主轴速比不稳定、主轴径向跳动、主轴同轴度、毛坯变形以及切削热等引起的误差。根据实切结果,对影响加工精度的主要因素进行了理论分析,提出适当的工艺改进方法,特别是对渐开线类零件进行分层切削,减小了加工误差。最后,给出各类零件的加工实例,证明了通用模型的可行性。通过本文的研究,摆线旋分机床扩大了其应用范围并达到了一定程度的通用性和有效性。文章最后还阐述了目前摆线旋分机床仍存在的需要进一步研究的问题,如切削速度以及切削热对加工精度的影响、加工过程中切削力的分析等。
At the present time,the machine tool with the method of cycloid rotational indexing method was still a special machine, so that it could not be used widely. This paper studied a lot by analyzing its theory and machining experiment for its universal character. First, the definition and equation of cycloid was expatiated based on the mathematical model of cycloid, and then the machining principle of cycloid rotational indexing was described. The part was sorted to three ones according to its surface character, even polygons and slots, odd polygons and involutes. Based on it, universal models were builded for the three kinds of parts. On condition that the approximate error was in allowable range, the optimization algorithm to fix cycloid parameters was given for the objective of the highest machining efficiency. According to the cycloid parameters, the NC program was developed. Through a lot of machining experiments, this paper described the process character of the machining method and the method to select tool material, and found out factors that impact on the process precision, such as approximate error of tool, instability of spindles’speed rate, radial tremor of spindle, heat in machine cut and so on. And then some proposals on process were bring forward, specially machining the involutes with two layers. The last, it was proved that the models were correct with sample parts. Based on the study of this paper, the application range of the machine in cycloid rotational indexing method was extended and the machine got a universal character at a certain extent. At the end of the paper, some problem was described which needed more study about the machine, such as speed of machining, heat of machining, analysis of machine cutting force and so on.
At the present time,the machine tool with the method of cycloid rotational indexing method was still a special machine, so that it could not be used widely. This paper studied a lot by analyzing its theory and machining experiment for its universal character. First, the definition and equation of cycloid was expatiated based on the mathematical model of cycloid, and then the machining principle of cycloid rotational indexing was described. The part was sorted to three ones according to its surface character, even polygons and slots, odd polygons and involutes. Based on it, universal models were builded for the three kinds of parts. On condition that the approximate error was in allowable range, the optimization algorithm to fix cycloid parameters was given for the objective of the highest machining efficiency. According to the cycloid parameters, the NC program was developed. Through a lot of machining experiments, this paper described the process character of the machining method and the method to select tool material, and found out factors that impact on the process precision, such as approximate error of tool, instability of spindles’speed rate, radial tremor of spindle, heat in machine cut and so on. And then some proposals on process were bring forward, specially machining the involutes with two layers. The last, it was proved that the models were correct with sample parts. Based on the study of this paper, the application range of the machine in cycloid rotational indexing method was extended and the machine got a universal character at a certain extent. At the end of the paper, some problem was described which needed more study about the machine, such as speed of machining, heat of machining, analysis of machine cutting force and so on.
引文
[1] 于会力,李佳,曹克伟,等. 一种加工汽车同步器齿套滑块槽的新方法. 汽车技术, 2003(9): 28~31
[2] 葛秀光,李佳,王丽萍,等. 摆线在多边形零件加工中的应用. 机床与液压, 2005(2): 45~47
[3] 高朋. 汽车同步器齿套倒锥摆线旋分加工法研究: (硕士学位论文). 天津: 天津大学机械工程学院, 2006
[4] 刘希玲,刘湘洪. 内摆线的平运动. 长沙铁道学院学报.1998,16(1):75~79
[5] STRAUCH M, HEINEMANN W. HEYM H U. Process for profiling toothed workpieces, especially for producing undercuts on gear tooth flanks of internally/externally toothed working gears, comprises machining a rotating workpiece using a rotating cutting edge tool. international patent, WO2005002770-A1, 2005-01-13
[6] 吴联银,魏洪钦,王小椿. 延伸外摆线锥齿轮的成形原理及齿面结构研究. 西安交通大学学报,2001,35(1):43~46
[7] 赖国庭,吴玉厚,富大伟,开放式数控系统的发展及性能研究. 机械与电子2003,(2):3~5
[8] 杨更更,叶佩青,杨开明. 基于 PMAC 的数控系统 PID 参数自适应调节. 机械工程师,2002(4):13~15
[9]吴玉厚,潘振宁,张珂,等. PMAC 控制器中 PID 调节的应用. 沈阳建筑工程学院学报,2004,20(2):153～157
[10]唐小会,谢寄石,黄大贵,等. 基于 PMAC 的开放式数控系统实验平台的研究与开发. 中国测试技术,2003(1):61~62
[11]杨晓京,张仲彦,李浙昆,等. 几种开放式微机数控系统比较. 制造业自动化,2002,24(1):18~21
[12] 丁峰,曲明昌,林延圻. 交流位置伺服系统 PID 控制方法实现. 电子机械工程,2003,19(1):52~54
[13]杜君文,邓广敏. 数控技术. 天津,天津大学出版社,2000
[14] 于会力. 汽车同步器齿套滑块槽加工机床数控系统开发: (硕士学位论文). 天津: 天津大学机械工程学院, 2004
[15]刘基博. 摆线族曲线的参数方程及其逼近圆. 机械传动,1992, 18(3): 8~13
[16]王保民. 关于摆线特性的研究. 机械科学与技术,2002,21(1):61~62
[17]夏小岩. 摆线铣削加工的应用. 汽齿科技,2002(1):23~28
[18]刘永新. 数学摆线在车床上进行多边形切削的应用. 木材加工机械,1999(1):13~15
[19] 朱建功,王忠. 摆线轨迹替代机构与车削多边形. 西南工学院学报,1996,11(3):38~40
[20]张彦博. 等误差圆弧逼近渐开线的节点计算新方法. 组合机床与自动化加工技术,2003(4):26~30
[21]L. M. SUNG, Y. C. TSAI. A study on the mathematical models and contact ratios of extended cycloid and cycloid bevel gear sets. Mechanism and Machine Theory, 1997, 32(1): 39~50
[22]龚劬. 二次曲线 Chebyshev 法向逼近的交换算法. 重庆大学学报, 1997(4):60~63
[23]高延新,高金良. 渐开线圆柱齿轮精度国家新标准简介. 机械工程师,2002(12):61~63
[24]李宁,徐俊,等. 电子齿轮原理及实现方法. 电器传动,2002,32(3):53~55
[25] 史恩秀,田晓虹,李永堂. 渐开线圆柱齿轮齿形误差的测量与计算. 太原重型机械学院学报,2000,21(1):18~21
[26] 龚劬,李平渊. 二次曲线最佳法向逼近的插值点优化迭代法. 高等学校计算数学学报,1995(3):223~229
[27]周卜生. 一类曲线段的最佳逼近圆. 机械传动,1994,18(2):43~46
[28] Ma Zhenqun, Gong Yanjue, Wang Xiaochun. A new generating method for the machining of a cylindrical gear with symmetric arcuate tooth trace. ACAD J XJTU 2004, 16(1):18~21
[29] S.Schofield , P.Wright. Open Architecture Controllers for Machine Tools, Part 1: Design Principles, Transaction of the ASME, 1998,(120):417~424
[30] J.V.Owen. Opening up controls architecture. Manufacturing Engineering, November, 1995: 53~60
[31] G.Pritschow, Ch.Daniel, G.Junghans. Open system controllers-A challenge for the future of the machine tool industry. Annals of the CIRP, 1993, (42):449~452
[32] 黄恺,李朝辉,苏铁明. 数控摆线插补算法探讨. 辽宁工学院学报,2000,20(4):11~13
[33] Pal-Chi Chang, Fu-Shou Wang, Jia-Huel Hwang, etc. Research on the design and manufacturing of an outer cycloid slotting cutter. Int Adv Manuf Techology, 2004(14)
[34] 孙全平,廖文和. 基于摆线的高速铣削刀轨生成算法研究. 机械制造,2003,41(465):12~14
[35] 郑友益,何晓玲. 两种型面曲线方程的推导. 洛阳工学院学报,1997,18(2):33~37
[36]黄仁贵. 主轴径向平面运动的几何分析. 机械工程学报,1994,30(2):26~31
[37]曹瑞. 同步器齿套倒锥齿加工工艺. 机械工艺师, 2001(5): 30
[38]黄开友. 机床主轴纯径向跳动对加工精度影响机理的研究. 现代机械,2003(6):43~45
[39] 李永祥,毕晓勤. 机床主轴回转误差对零件加工精度的影响. 河南工业大学学报,2005,26(3):57~62
[40] 阎树田,张思成,胡立志,等. 金属切削机床主轴运动误差影响的数学分析. 中国机械工程,2002,13(9):737~740
[41]郑焕文.机械制造工艺学.北京:高等教育出版社,1994.127～130.
[42]申永胜. 机械原理教程. 北京:清华大学出版社,1999
[43]刘宏友,彭锋. MATLAB 6.x 符号运算及其应用. 北京:机械工业出版社,2003.12
[2] 葛秀光,李佳,王丽萍,等. 摆线在多边形零件加工中的应用. 机床与液压, 2005(2): 45~47
[3] 高朋. 汽车同步器齿套倒锥摆线旋分加工法研究: (硕士学位论文). 天津: 天津大学机械工程学院, 2006
[4] 刘希玲,刘湘洪. 内摆线的平运动. 长沙铁道学院学报.1998,16(1):75~79
[5] STRAUCH M, HEINEMANN W. HEYM H U. Process for profiling toothed workpieces, especially for producing undercuts on gear tooth flanks of internally/externally toothed working gears, comprises machining a rotating workpiece using a rotating cutting edge tool. international patent, WO2005002770-A1, 2005-01-13
[6] 吴联银,魏洪钦,王小椿. 延伸外摆线锥齿轮的成形原理及齿面结构研究. 西安交通大学学报,2001,35(1):43~46
[7] 赖国庭,吴玉厚,富大伟,开放式数控系统的发展及性能研究. 机械与电子2003,(2):3~5
[8] 杨更更,叶佩青,杨开明. 基于 PMAC 的数控系统 PID 参数自适应调节. 机械工程师,2002(4):13~15
[9]吴玉厚,潘振宁,张珂,等. PMAC 控制器中 PID 调节的应用. 沈阳建筑工程学院学报,2004,20(2):153～157
[10]唐小会,谢寄石,黄大贵,等. 基于 PMAC 的开放式数控系统实验平台的研究与开发. 中国测试技术,2003(1):61~62
[11]杨晓京,张仲彦,李浙昆,等. 几种开放式微机数控系统比较. 制造业自动化,2002,24(1):18~21
[12] 丁峰,曲明昌,林延圻. 交流位置伺服系统 PID 控制方法实现. 电子机械工程,2003,19(1):52~54
[13]杜君文,邓广敏. 数控技术. 天津,天津大学出版社,2000
[14] 于会力. 汽车同步器齿套滑块槽加工机床数控系统开发: (硕士学位论文). 天津: 天津大学机械工程学院, 2004
[15]刘基博. 摆线族曲线的参数方程及其逼近圆. 机械传动,1992, 18(3): 8~13
[16]王保民. 关于摆线特性的研究. 机械科学与技术,2002,21(1):61~62
[17]夏小岩. 摆线铣削加工的应用. 汽齿科技,2002(1):23~28
[18]刘永新. 数学摆线在车床上进行多边形切削的应用. 木材加工机械,1999(1):13~15
[19] 朱建功,王忠. 摆线轨迹替代机构与车削多边形. 西南工学院学报,1996,11(3):38~40
[20]张彦博. 等误差圆弧逼近渐开线的节点计算新方法. 组合机床与自动化加工技术,2003(4):26~30
[21]L. M. SUNG, Y. C. TSAI. A study on the mathematical models and contact ratios of extended cycloid and cycloid bevel gear sets. Mechanism and Machine Theory, 1997, 32(1): 39~50
[22]龚劬. 二次曲线 Chebyshev 法向逼近的交换算法. 重庆大学学报, 1997(4):60~63
[23]高延新,高金良. 渐开线圆柱齿轮精度国家新标准简介. 机械工程师,2002(12):61~63
[24]李宁,徐俊,等. 电子齿轮原理及实现方法. 电器传动,2002,32(3):53~55
[25] 史恩秀,田晓虹,李永堂. 渐开线圆柱齿轮齿形误差的测量与计算. 太原重型机械学院学报,2000,21(1):18~21
[26] 龚劬,李平渊. 二次曲线最佳法向逼近的插值点优化迭代法. 高等学校计算数学学报,1995(3):223~229
[27]周卜生. 一类曲线段的最佳逼近圆. 机械传动,1994,18(2):43~46
[28] Ma Zhenqun, Gong Yanjue, Wang Xiaochun. A new generating method for the machining of a cylindrical gear with symmetric arcuate tooth trace. ACAD J XJTU 2004, 16(1):18~21
[29] S.Schofield , P.Wright. Open Architecture Controllers for Machine Tools, Part 1: Design Principles, Transaction of the ASME, 1998,(120):417~424
[30] J.V.Owen. Opening up controls architecture. Manufacturing Engineering, November, 1995: 53~60
[31] G.Pritschow, Ch.Daniel, G.Junghans. Open system controllers-A challenge for the future of the machine tool industry. Annals of the CIRP, 1993, (42):449~452
[32] 黄恺,李朝辉,苏铁明. 数控摆线插补算法探讨. 辽宁工学院学报,2000,20(4):11~13
[33] Pal-Chi Chang, Fu-Shou Wang, Jia-Huel Hwang, etc. Research on the design and manufacturing of an outer cycloid slotting cutter. Int Adv Manuf Techology, 2004(14)
[34] 孙全平,廖文和. 基于摆线的高速铣削刀轨生成算法研究. 机械制造,2003,41(465):12~14
[35] 郑友益,何晓玲. 两种型面曲线方程的推导. 洛阳工学院学报,1997,18(2):33~37
[36]黄仁贵. 主轴径向平面运动的几何分析. 机械工程学报,1994,30(2):26~31
[37]曹瑞. 同步器齿套倒锥齿加工工艺. 机械工艺师, 2001(5): 30
[38]黄开友. 机床主轴纯径向跳动对加工精度影响机理的研究. 现代机械,2003(6):43~45
[39] 李永祥,毕晓勤. 机床主轴回转误差对零件加工精度的影响. 河南工业大学学报,2005,26(3):57~62
[40] 阎树田,张思成,胡立志,等. 金属切削机床主轴运动误差影响的数学分析. 中国机械工程,2002,13(9):737~740
[41]郑焕文.机械制造工艺学.北京:高等教育出版社,1994.127～130.
[42]申永胜. 机械原理教程. 北京:清华大学出版社,1999
[43]刘宏友,彭锋. MATLAB 6.x 符号运算及其应用. 北京:机械工业出版社,2003.12