磁流变自抑振智能镗杆的理论与方法研究
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摘要
针对精密孔加工中常见的颤振问题,本论文结合国家自然科学基金“基于磁流变液自抑振的智能镗杆构件理论和方法研究”(项目编号:50405036)和浙江省自然科学基金“磁流变液自抑振智能镗杆构件理论和方法研究”(项目编号:Y104462),通过理论分析、数值仿真及实验验证,对应用磁流变技术抑制镗削过程中的切削颤振问题进行了深入系统的研究。
第1章,阐述了本学位论文的研究背景与意义,详细介绍了国内外对切削颤振控制技术的研究现状,明确了机床切削颤振控制技术的发展方向,提出了论文的主要研究内容。
第2章,建立了镗削加工系统的颤振动力学模型,研究了颤振发生的根本原因,同时对主轴变速切削方法的颤振抑制机理进行了研究,得到了其颤振抑制的本质原因。在此基础上,对结构刚度和阻尼变化对系统稳定性的影响进行了深入研究,提出了变结构刚度的颤振抑制方法,并从理论上证实了它与变速切削法具有异曲同工之效。
第3章,基于磁流变液材料的特点,提出了支撑刚度可控型的磁流变自抑振智能镗杆设计方案,并对关键结构磁流变液抑振单元进行了参数优化。应用有限元ANSYS仿真分析了优化后的结构参数,结果表明主要性能指标均达到了设计要求。
第4章,首先通过静态加载法对智能镗杆的刚度和阻尼特性进行测试,发现在施加磁场后镗杆静柔度和阻尼特性变化明显;其次采用瞬态激振法和稳态激振法分别对智能镗杆进行了动态特性测试分析,研究了智能镗杆的刚度与阻尼关于磁场强度大小的变化规律及其动态特性与激振频率、幅值和磁场强度之间的关系;最后对智能镗杆的响应时间进行了测试。研究得到的磁流变自抑振智能镗杆的静动态特性变化规律和模型,将为有效制定其控制策略提供了科学依据。
第5章,提出了一种基于Kelvin模型和Maxwell模型的磁流变液材料本构模型,建立了基于Euler-Bernoulli梁模型的磁流变自抑振智能镗杆动力学模型,并借助含耗散函数的拉格朗日方程对智能镗杆的动态特性进行了理论分析与数值仿真。为了满足实时控制的要求,又引入了Bouc-Wen模型,建立了基于此模型的智能镗杆动力学模型,并用非线性最小二乘法理论对相关参数进行了识别,最后进行了数值仿真研究,结果表明它能准确地描述智能镗杆的动力学特性,为后续制定实时控制策略打下基础。
第6章,根据镗削过程中颤振产生、发展和成熟各个阶段的特点,把整个镗削过程分成两种情况,并在此基础上分别提出了非线性随机最优半主动控制策略和变刚度半主动控制策略。针对非线性随机最优半主动控制策略,对其控制律进行了推导,同时提出了相应的性能准则,并进行了控制仿真分析。针对变刚度半主动控制策略,对其控制参数优选进行了理论分析,并做了相关数值仿真研究。
第7章,为了验证前面提出的理论和方法的正确性,在车床CA6140上建立了磁流变自抑振智能镗杆的切削颤振控制实验平台,进行了相关实验研究。首先对非线性随机最优半主动控制策略进行了切削颤振控制实验,考察了其实际的减振效果,并验证了理论分析结果的正确性。其次对变刚度半主动控制策略进行了切削颤振抑制实验,并通过实验方法验证了控制参数优化结果的合理性。
第8章,总结了论文的主要研究工作和创新点,并展望了未来的研究工作。
The chatter always occurs in precision hole boring process, which is one of the main abnormal cutting conditions that influences the quality of workpicece. To solve this problem, the cutting chatter suppression in boring process was studied systematically in this dissertation . The research work is supported by the National Natural Science Foundation of China (Grant No. 50405036), "Research on the Theory and Method for Intelligent Boring Bar with Self-Chatter-Suppression Based on Magnetorheological Fluid ", and the Natural Science Foundation of Zhejiang Province (Grant No. Y104462), "Research on the Theory and Method for MR Intelligent Boring Bar with Self-Chatter-Suppression". And the rearsearch work was carried out by combining theoretical analysis, numerical simulation with experimental verification.
In Chapter 1, the background and significance of the research were introduced, the development trend and current research situations of the technology of cutting chatter suppression were expatiated, then the research contents of this dissertation were proposed.
In Chapter 2, the dynamic model of regenerative chatter is established, which is the main type chatter in boring process. Then, the chatter suppression mechanisms of variable speed cutting method was analyzed. Lastly, the variable structural stiffness method of chatter suppression was proposed. By comparing, it was found that the chatter suppression mechanism of variable speed cutting method is similar to variable structural stiffness method.
In Chapter 3, a MR intelligent boring bar with self-chatter-suppression was proposed, whose stiffness and natural frequency are controllable. The structural parameters of MR chatter suppression unit was optimized, which is the key part of the MR intelligent boring bar. Lastly, the optimized results was validated by finite element analysis, and the simulation results show that the main performance of MR intelligent boring bar meet the design requirments.
In Chapter 4, firstly, the stiffness and damping of MR intelligent boring bar were tested by static loading method, and the results show that the static stiffness and damping will increase obviously when the magnetic intensity increased. Secondly, the variable laws of the system stiffness and damping were investigated by transient exciting method by applying different magnetic intensity, and the results show that when the magnetic intensity increased, the stiffness of MR intelligent boring bar will increase monotonously, while the damping will firstly increased and then decreased. Thirdly, the intelligent boring bar was tested by steady state exciting method, and the results show that the system dynamic characteristics are influenced by vibration amplitude, frequency and magnetic intensity. Lastly, the dynamic response time of MR intelligent boring bar was tested.
In Chapter 5, the constitutive model of MR fluid was established on the basis of Kelvin model and Maxwell model, and the results of numerical analysis show that the model can describe the MR fluid's dynamic characteristics accurately. Then, the dynamic model of MR intelligent boring bar was established based on the constitutive model of MR fluid, and its characteristics was analyzed by Lagrange equation. To meet the requirement of real-time control, a dynamic model of MR intelligent boring bar based on Bouc-Wen model was proposed. Then, the parameters of model was identified by nonlinear least square method. Lastly, the numerical simulation of the model was carried out, and the results show that it can discribe the dynamic characteristics of MR intelligent boring bar accurately.
In Chapter 6, according to the characteristics of chatter development process, the boring process can be divided into two cases. On this basis, the nonlinear stochastic optimal semi-active control strategy and the varying stiffness semi-active control strategy were proposed respectively. Then, the control law of nonlinear stochastic optimal semi-active control strategy was derived, and the numerical simulation analysis was carried out. Lastly, the control parameters of varying stiffness semi-active control strategy was optimized by way of the theory analysis, and in addition, the numerical simulation was carried out.
In Chapter 7, to verify the theory and method mentioned above, the experimental setup of MR intelligent boring bar was built on the CA6140 type lathe. A series of experiments were carried out, and the results show that the method can suppress chatter efficiently and surface quality of workpiece can be improved significantly.
In Chapter 8, the chief work and innovations of this dissertation were summarized, and the further research subjects were proposed.
第1章,阐述了本学位论文的研究背景与意义,详细介绍了国内外对切削颤振控制技术的研究现状,明确了机床切削颤振控制技术的发展方向,提出了论文的主要研究内容。
第2章,建立了镗削加工系统的颤振动力学模型,研究了颤振发生的根本原因,同时对主轴变速切削方法的颤振抑制机理进行了研究,得到了其颤振抑制的本质原因。在此基础上,对结构刚度和阻尼变化对系统稳定性的影响进行了深入研究,提出了变结构刚度的颤振抑制方法,并从理论上证实了它与变速切削法具有异曲同工之效。
第3章,基于磁流变液材料的特点,提出了支撑刚度可控型的磁流变自抑振智能镗杆设计方案,并对关键结构磁流变液抑振单元进行了参数优化。应用有限元ANSYS仿真分析了优化后的结构参数,结果表明主要性能指标均达到了设计要求。
第4章,首先通过静态加载法对智能镗杆的刚度和阻尼特性进行测试,发现在施加磁场后镗杆静柔度和阻尼特性变化明显;其次采用瞬态激振法和稳态激振法分别对智能镗杆进行了动态特性测试分析,研究了智能镗杆的刚度与阻尼关于磁场强度大小的变化规律及其动态特性与激振频率、幅值和磁场强度之间的关系;最后对智能镗杆的响应时间进行了测试。研究得到的磁流变自抑振智能镗杆的静动态特性变化规律和模型,将为有效制定其控制策略提供了科学依据。
第5章,提出了一种基于Kelvin模型和Maxwell模型的磁流变液材料本构模型,建立了基于Euler-Bernoulli梁模型的磁流变自抑振智能镗杆动力学模型,并借助含耗散函数的拉格朗日方程对智能镗杆的动态特性进行了理论分析与数值仿真。为了满足实时控制的要求,又引入了Bouc-Wen模型,建立了基于此模型的智能镗杆动力学模型,并用非线性最小二乘法理论对相关参数进行了识别,最后进行了数值仿真研究,结果表明它能准确地描述智能镗杆的动力学特性,为后续制定实时控制策略打下基础。
第6章,根据镗削过程中颤振产生、发展和成熟各个阶段的特点,把整个镗削过程分成两种情况,并在此基础上分别提出了非线性随机最优半主动控制策略和变刚度半主动控制策略。针对非线性随机最优半主动控制策略,对其控制律进行了推导,同时提出了相应的性能准则,并进行了控制仿真分析。针对变刚度半主动控制策略,对其控制参数优选进行了理论分析,并做了相关数值仿真研究。
第7章,为了验证前面提出的理论和方法的正确性,在车床CA6140上建立了磁流变自抑振智能镗杆的切削颤振控制实验平台,进行了相关实验研究。首先对非线性随机最优半主动控制策略进行了切削颤振控制实验,考察了其实际的减振效果,并验证了理论分析结果的正确性。其次对变刚度半主动控制策略进行了切削颤振抑制实验,并通过实验方法验证了控制参数优化结果的合理性。
第8章,总结了论文的主要研究工作和创新点,并展望了未来的研究工作。
The chatter always occurs in precision hole boring process, which is one of the main abnormal cutting conditions that influences the quality of workpicece. To solve this problem, the cutting chatter suppression in boring process was studied systematically in this dissertation . The research work is supported by the National Natural Science Foundation of China (Grant No. 50405036), "Research on the Theory and Method for Intelligent Boring Bar with Self-Chatter-Suppression Based on Magnetorheological Fluid ", and the Natural Science Foundation of Zhejiang Province (Grant No. Y104462), "Research on the Theory and Method for MR Intelligent Boring Bar with Self-Chatter-Suppression". And the rearsearch work was carried out by combining theoretical analysis, numerical simulation with experimental verification.
In Chapter 1, the background and significance of the research were introduced, the development trend and current research situations of the technology of cutting chatter suppression were expatiated, then the research contents of this dissertation were proposed.
In Chapter 2, the dynamic model of regenerative chatter is established, which is the main type chatter in boring process. Then, the chatter suppression mechanisms of variable speed cutting method was analyzed. Lastly, the variable structural stiffness method of chatter suppression was proposed. By comparing, it was found that the chatter suppression mechanism of variable speed cutting method is similar to variable structural stiffness method.
In Chapter 3, a MR intelligent boring bar with self-chatter-suppression was proposed, whose stiffness and natural frequency are controllable. The structural parameters of MR chatter suppression unit was optimized, which is the key part of the MR intelligent boring bar. Lastly, the optimized results was validated by finite element analysis, and the simulation results show that the main performance of MR intelligent boring bar meet the design requirments.
In Chapter 4, firstly, the stiffness and damping of MR intelligent boring bar were tested by static loading method, and the results show that the static stiffness and damping will increase obviously when the magnetic intensity increased. Secondly, the variable laws of the system stiffness and damping were investigated by transient exciting method by applying different magnetic intensity, and the results show that when the magnetic intensity increased, the stiffness of MR intelligent boring bar will increase monotonously, while the damping will firstly increased and then decreased. Thirdly, the intelligent boring bar was tested by steady state exciting method, and the results show that the system dynamic characteristics are influenced by vibration amplitude, frequency and magnetic intensity. Lastly, the dynamic response time of MR intelligent boring bar was tested.
In Chapter 5, the constitutive model of MR fluid was established on the basis of Kelvin model and Maxwell model, and the results of numerical analysis show that the model can describe the MR fluid's dynamic characteristics accurately. Then, the dynamic model of MR intelligent boring bar was established based on the constitutive model of MR fluid, and its characteristics was analyzed by Lagrange equation. To meet the requirement of real-time control, a dynamic model of MR intelligent boring bar based on Bouc-Wen model was proposed. Then, the parameters of model was identified by nonlinear least square method. Lastly, the numerical simulation of the model was carried out, and the results show that it can discribe the dynamic characteristics of MR intelligent boring bar accurately.
In Chapter 6, according to the characteristics of chatter development process, the boring process can be divided into two cases. On this basis, the nonlinear stochastic optimal semi-active control strategy and the varying stiffness semi-active control strategy were proposed respectively. Then, the control law of nonlinear stochastic optimal semi-active control strategy was derived, and the numerical simulation analysis was carried out. Lastly, the control parameters of varying stiffness semi-active control strategy was optimized by way of the theory analysis, and in addition, the numerical simulation was carried out.
In Chapter 7, to verify the theory and method mentioned above, the experimental setup of MR intelligent boring bar was built on the CA6140 type lathe. A series of experiments were carried out, and the results show that the method can suppress chatter efficiently and surface quality of workpiece can be improved significantly.
In Chapter 8, the chief work and innovations of this dissertation were summarized, and the further research subjects were proposed.
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