基于光纤光栅的铣削力测量方法基础研究
|
摘要
随着生产自动化和现代加工制造技术的迅速发展,以数控机床、加工中心为代表的数字化加工设备已经成为现代制造技术的主流。为了保障这些高精自动化加工设备的加工质量和运行安全,迫切需要发展新型、实用、可靠的加工过程监控系统。铣削是生产中最常用的加工方式之一,铣削时铣削力的变化规律直接影响到铣削用量的制定及加工表面的质量,因此在机械加工日益自动化、智能化的环境下,刀具的磨损检测和刀具的断裂识别是不可或缺的。刀具加工状态监测将成为数控加工技术的核心内容与研究的热点。目前在刀具状态监测方面,主要以加工中切削力的测量为主,它能直接反映加工过程中的刀具状态,能够探测刀具的磨损和断裂情况。
光纤光栅传感器是一种性能独特的新型光测传感器,其主要优点有：一是防爆、抗电磁干扰且是优良的绝缘体；二是耐腐蚀,可在酸碱等复杂的化学环境中使用；三是体积小、重量轻,可安装在狭小的空间或者埋入结构的内部；四是灵敏度和可靠性高并且易于实现数字化传感；五是单根光纤上能够布置多个光栅,以实现针对不同或相同参数的分布式传感等优点。光纤光栅传感器的以上优点满足切削力多个分量同时在线检测要求并适用于铣削加工环境,能够实现铣削力的准确测量。
本文主要研究将光纤光栅传感器应用于刀具铣削力的测量系统中,论文具体研究工作如下：
(1)转换弹性体是铣削力测量中的敏感元件,决定了铣削力的可测性。通过对数控机床铣削过程的研究,理论分析和有限元仿真分析相结合的方式揭示铣削力导致的转换弹性体的应变分布规律,建立铣削力与弹性体应变之间的映射关系,提出转换弹性体的结构优化设计方法。
(2)研究基于电阻应变片和光纤光栅传感的测力系统结构及传感器布置方案,对八角环进行单独的静态标定实验。对比电阻应变片和光栅传感器测量数据,分析两种传感器测量的优缺点,验证了光纤光栅在铣削力测量方面的可测性和准确性。
With the accelerating development of industrial automation and modern manufacturing, numerical control machine and machining center have become the mainstream of modern manufacturing technology. In order to guarantee the safe operation and processing quality of these high-cost automatic processing equipments, it is in urgent need of new, practical and reliable monitoring system to monitor the dynamic milling process of processing system and forecast the tool wear and fracture conditions. Milling process is primarily involves milling parameters and tool condition. For the purpose of enhancing productivity and reducing production costs, under full automatic processing environment, the effective monitoring of tool conditions is the nucleus of machine tooling monitoring as well as the research hotspot. Currently, in the field of tool condition monitoring, the measurement of milling force is the most popular method. It can straightly reflect the tool conditions during course of working and detect tool wear and fracture conditions.
Fiber grating sensor is a new flash ranging sensor. It characterizes by small volume, explosion prevention, electric insulation, anti-electromagnetic interference, high precision, high reliability, excellent environment suitability and the grating can deploy in a single fiber several measurements directed at different or similar parameters to form distributed transduction, which satisfy the requirements of multiple components of turning force in conducting on-line monitoring, adapt to the processing environment of turning force measurement so as to realize the accurate measurement. Given this background, this paper puts forward the application of fiber grating sensor technology into tool milling force measurement system. This paper has gained the following fruits:
First, conversion elastomer is a sensitive component in measuring milling force and it determines the testability of milling force. Through the combined use of process research, theoretic analysis and simulation of finite element analysis into the numerical control machine milling, this paper reveals the distribution rule of conversion elastomer strain caused by milling force, establishes the mapping relations between milling force and elastomer strain, and proposes the structural optimization designing method of elastomer.
Second, a set of milling force measuring system based on fiber grating is developed in the paper. Research octagonal ring milling force measurement system based on the strain gauges and fiber grating sensors, research the sensors arrangement. Contrast metrical data of strain gauges and grating sensors, it is indicated that fiber bragg grating sensor can be a reliable method to measure turning force.
光纤光栅传感器是一种性能独特的新型光测传感器,其主要优点有：一是防爆、抗电磁干扰且是优良的绝缘体；二是耐腐蚀,可在酸碱等复杂的化学环境中使用；三是体积小、重量轻,可安装在狭小的空间或者埋入结构的内部；四是灵敏度和可靠性高并且易于实现数字化传感；五是单根光纤上能够布置多个光栅,以实现针对不同或相同参数的分布式传感等优点。光纤光栅传感器的以上优点满足切削力多个分量同时在线检测要求并适用于铣削加工环境,能够实现铣削力的准确测量。
本文主要研究将光纤光栅传感器应用于刀具铣削力的测量系统中,论文具体研究工作如下：
(1)转换弹性体是铣削力测量中的敏感元件,决定了铣削力的可测性。通过对数控机床铣削过程的研究,理论分析和有限元仿真分析相结合的方式揭示铣削力导致的转换弹性体的应变分布规律,建立铣削力与弹性体应变之间的映射关系,提出转换弹性体的结构优化设计方法。
(2)研究基于电阻应变片和光纤光栅传感的测力系统结构及传感器布置方案,对八角环进行单独的静态标定实验。对比电阻应变片和光栅传感器测量数据,分析两种传感器测量的优缺点,验证了光纤光栅在铣削力测量方面的可测性和准确性。
With the accelerating development of industrial automation and modern manufacturing, numerical control machine and machining center have become the mainstream of modern manufacturing technology. In order to guarantee the safe operation and processing quality of these high-cost automatic processing equipments, it is in urgent need of new, practical and reliable monitoring system to monitor the dynamic milling process of processing system and forecast the tool wear and fracture conditions. Milling process is primarily involves milling parameters and tool condition. For the purpose of enhancing productivity and reducing production costs, under full automatic processing environment, the effective monitoring of tool conditions is the nucleus of machine tooling monitoring as well as the research hotspot. Currently, in the field of tool condition monitoring, the measurement of milling force is the most popular method. It can straightly reflect the tool conditions during course of working and detect tool wear and fracture conditions.
Fiber grating sensor is a new flash ranging sensor. It characterizes by small volume, explosion prevention, electric insulation, anti-electromagnetic interference, high precision, high reliability, excellent environment suitability and the grating can deploy in a single fiber several measurements directed at different or similar parameters to form distributed transduction, which satisfy the requirements of multiple components of turning force in conducting on-line monitoring, adapt to the processing environment of turning force measurement so as to realize the accurate measurement. Given this background, this paper puts forward the application of fiber grating sensor technology into tool milling force measurement system. This paper has gained the following fruits:
First, conversion elastomer is a sensitive component in measuring milling force and it determines the testability of milling force. Through the combined use of process research, theoretic analysis and simulation of finite element analysis into the numerical control machine milling, this paper reveals the distribution rule of conversion elastomer strain caused by milling force, establishes the mapping relations between milling force and elastomer strain, and proposes the structural optimization designing method of elastomer.
Second, a set of milling force measuring system based on fiber grating is developed in the paper. Research octagonal ring milling force measurement system based on the strain gauges and fiber grating sensors, research the sensors arrangement. Contrast metrical data of strain gauges and grating sensors, it is indicated that fiber bragg grating sensor can be a reliable method to measure turning force.
引文
[1]张世昌.先进制造技术[M].天津：天津大学出版社,2004：1-16.
[2]李圣怡,吴学忠,范大鹏.多传感器融合理论及其在智能制造系统中的应用[J],长沙：国防科技大学出版社,1998：364-390.
[3]R. Teti, K. Jemielniak, G. O'Donnell,et al. Advanced monitoring of machining operations[J]. CIRP Annals - Manufacturing Technology,2010,59:717-739.
[4]M. Lanzetta. A new flexible high-resolution vision sensor for tool condition monitoring[J]. Journal of Materials Processing Techology,2001,119:73-82.
[5]Wong Y. S, Yuen W. K, Lee K. S etc. Machine vision monitoring of tool wear[J], Proceedings of SPIE. The International Society for Optical Engineering,1998,3518:17-24.
[6]Korkut. A dynamometer design and its construction for milling operation[J]. Materials and Design,2003,24:631-637.
[7]Suleyman Yaldiz, Faruk Unsacar. Design, development and testing of a turning dynamometer for cutting force measurement[J]. Materials and Design,2006, (27):839-846.
[8]Suleyman Yaldiz, Faruk Unsacar. A dynamometer design for measurement the cutting forces on turning. measurement[J].Materials and Design 2006, (39):80-89.
[9]Suleyman Yaldiz, Faruk Unsacar, Haci Saglam,et al. Design, development and testing of a four-component milling dynamometer for the measurement of cutting force and torque[J]. Materials and Design,2007, (217):1499-1511.
[10]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,2007,28:496-506.
[11]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,2007,28: 673-685.
[12]Xiaoli Li. A brief review:Acoustic emission method for tool wear monitoring during turning. International Journal of Machine Tools&Manufacture,2002,42:157-165.
[13]Govekar E, Gradisek J, Grabec. Analysis of AE signals and monitoring of machining processes[J]. Ultrasonics 2000,38:598-603.
[14]谢政,王敏,范伟,邵华.基于铣削噪声的刀具状态监测研究.工具技术[J].2008,47(7)：19-21.
[15]王忠民,王信义,杨大勇等.刀具磨损状态在线监测技术[J],制造技术与机床,2000,6：39-41.
[16]陈爱弟,王信义,王忠民等.用于监测刀具磨损的声发射特征优选方法[J],北京理工大学学报,2000,，2(3)：270-274.
[17]郑力.一个应用于自动化加工系统的综合刀具监测系统[J]，机械工程学报：1991(10)：7-11.
[18]Kristo, sheng Huang, et,at. Detecting tool breakage using accelerometer in ball-nose end milling[C].10th. Intl Conf. on Automation Robotics and Vision.2008,12:17-21.
[19]曹伟青.B样条模糊神经网络在刀具故障诊断中的应用[D].西南交通大学硕士研究生学位论文,2005.12：18-26.
[20]刘志艳等.刀具破损在线监测及其系统的研究[J].燕山大学学报,1998,4：127-128.
[21]Tamas Szecsi, A DC motor based cutting tool condition monitoring system[J], Journal of Materials Processing Technology,1999,92:350-354.
[22]Luis Alfonso Franco-Gasca, Gilberto Herrera-Ruiz, Rocio Peniche-Vera, Rene de Jesus Romero-Troncoso, Wbaldo Leal-Tafolla. Sensorless tool failure monitoring system for drilling machines[J]. International Journal of Machine Tools & Manufacture,2006, 46:381-386.
[23]Li Xiaoli, Ouyang Gaoxiang, Liang Zhenhu. Complexity measure of motor current signals for tool flute breakage detection in end milling[J]. International Journal of Machine Tools & Manufacture,2008,48:371-379.
[24]徐顺利等.用切削功率进行刀具磨损在线监测研究[J].轴承,1995(8)：16-18.
[25]甘启义等.机床功率监控技术中一种新的监控特征量[J].组合机床与自动化加工技术,1992,10：20-22.
[26]Axinte D, Gindy N, Fox K, Unanue. Process monitoring to assist the workpiece surface quality in machining[J]. International Journal of Machine Tools and Manufacture,2004, 44:1091-1098.
[27]梁德沛,李宝丽.机械工程参量的动态测量技术[M],北京：机械工业出版社,1995：168-177.
[28]秦自楷.压电石英晶体[M].第一版,北京：国防工业出版社,1980.
[29]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.
[30]Kim J-D, Kim D-S. Development of a combined type tool dynamometer with a piezo-film cccelerometer for an ultra-precision lathe [J].Journal of Materials Processing Technology, 1997,71:360-366.
[31]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,1995(5)：3-7.
[32]唐偃生,韩永澎.GH-H实体压磁式测力仪的研制与应用[J].工业计量,2002(5)：41-42.
[33]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.
[34]Martin B. Jun. O. Burak Ozdoganlar, Andreas Kirchheim,et al. Evaluation of a spindle-based force sensor for monitoring and fault diagnosis of machining operations[J]. International Journal of Machine Tools & Manufacture 42 (2002) 741-751.
[35]刘晓玲.新型压电动态切削测力系统的结构设汁与优化分析[D].大连：大连理工大学,2005.03.
[36]卢江月.三向压电式车削测力系统的研制[D].大连：大连理工大学,2008.12.
[37]张铁.三向压电式车削测力系统的性能研究与结构设计[D].大连：大连理工大学,2007.12.
[38]卢江跃,孙宝元,张军,等.YDC—11189车削测力系统性能改进研究[J].传感器与微系统,2009,28(6)：22-24.
[39]谢印国.高能材料HEM切削力测试系统的研制[D].大连：大连理工大学,2007.12.
[40]韩丽丽,孙宝元,钱敏.新型压电三向钻削测力系统的设计与实验研究[J].压电与声光,2007,29(3)：283-289.
[41]W Morey, G. Meltz, W H Glenn. Fiber potic bragg grating sensors. Pr oc SPI E.1989, 1169: 98-107.
[42]姜德生,何伟.光纤光栅传感器的应用概况.[J]光电子激光.2002,13(4)：420-430.
[43]姜德生,梁磊等.光纤光栅传感技术在重大工程结构监测中的应用[C].2001年国家自然科基金委员会重大工程灾变行为与健康监测学术研讨会.
[44]刘胜春,姜德生等.光纤光栅测力传感器的研究及应用.[J]武汉理工大学学报.2006,30(2)：209-211.
[45]南秋明.光纤光栅测力环在悬索桥索力监测中应用.[J]公路交通科技.2010,27(3)：64-68.
[46]Suresh R, Tjin S C Ngo NQ. Shear force sensing by strain transformation using non-rectilinearly embedded fiber bragg grating[J]. Sensors and Actuators A:Physical.2004, 116:(1) 107-118.
[47]张伟刚,李红民,开桂云等.轮辐式温度自动补偿型光纤光栅测力传感器.[J]中国激光.2005,32(7)：957-960.
[48]刘兆妍,雷震山.应用光纤光栅和虚拟仪器的切削力测量技术[J].大连理工大学学报,2005,39(10)：53-55.
[49]李宏男,任亮等.结构健康检测光纤光栅传感技术[M].北京：中国建筑工业出版社,2008
[50]Mousumi M, Tarun K G, Ashim K C. et al. Fibre bragg gratings in structural health monitoring-present status and applications[J]. Sensors and Actuators A 147 (2008) 150-164.
[50]周建华.光纤光栅传感器应变传递特性研究[D].武汉：武汉理工大学,2010.05.
[51]赵芝眉.电阻应变片式测力仪布片方法的讨论[J].南京工学院学报,1980,3：87-99.
[52]王娟.三维动态切削测力仪结构参数优化[D].北京：北方工业大学,2009.05.
[53]袁哲俊.电阻应变片式测力仪设计中几个问题的探讨[D].哈尔滨工业大学,1979.
[54]陶晓亮.基于光纤Bragg光栅传感的车削力测量系统研究[D].武汉：武汉理工大学,2011.05.
[55]沙俊.新型铣削测力仪[D].机械工程师,1987,4：34-36.
[56]阮鸿雁,王勇.加长八角环测力系统的优化设计[J].江苏工学院学报,1985,1：76-87.
[57]邓平凡ANSYS有限元自学手册[M].北京：人民邮电出版社,2007.
[58]张志涌,徐彦琴MATLAB教程—基于6.X版本[M].北京：北京航空航天出版社,2001.
[2]李圣怡,吴学忠,范大鹏.多传感器融合理论及其在智能制造系统中的应用[J],长沙：国防科技大学出版社,1998：364-390.
[3]R. Teti, K. Jemielniak, G. O'Donnell,et al. Advanced monitoring of machining operations[J]. CIRP Annals - Manufacturing Technology,2010,59:717-739.
[4]M. Lanzetta. A new flexible high-resolution vision sensor for tool condition monitoring[J]. Journal of Materials Processing Techology,2001,119:73-82.
[5]Wong Y. S, Yuen W. K, Lee K. S etc. Machine vision monitoring of tool wear[J], Proceedings of SPIE. The International Society for Optical Engineering,1998,3518:17-24.
[6]Korkut. A dynamometer design and its construction for milling operation[J]. Materials and Design,2003,24:631-637.
[7]Suleyman Yaldiz, Faruk Unsacar. Design, development and testing of a turning dynamometer for cutting force measurement[J]. Materials and Design,2006, (27):839-846.
[8]Suleyman Yaldiz, Faruk Unsacar. A dynamometer design for measurement the cutting forces on turning. measurement[J].Materials and Design 2006, (39):80-89.
[9]Suleyman Yaldiz, Faruk Unsacar, Haci Saglam,et al. Design, development and testing of a four-component milling dynamometer for the measurement of cutting force and torque[J]. Materials and Design,2007, (217):1499-1511.
[10]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,2007,28:496-506.
[11]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,2007,28: 673-685.
[12]Xiaoli Li. A brief review:Acoustic emission method for tool wear monitoring during turning. International Journal of Machine Tools&Manufacture,2002,42:157-165.
[13]Govekar E, Gradisek J, Grabec. Analysis of AE signals and monitoring of machining processes[J]. Ultrasonics 2000,38:598-603.
[14]谢政,王敏,范伟,邵华.基于铣削噪声的刀具状态监测研究.工具技术[J].2008,47(7)：19-21.
[15]王忠民,王信义,杨大勇等.刀具磨损状态在线监测技术[J],制造技术与机床,2000,6：39-41.
[16]陈爱弟,王信义,王忠民等.用于监测刀具磨损的声发射特征优选方法[J],北京理工大学学报,2000,，2(3)：270-274.
[17]郑力.一个应用于自动化加工系统的综合刀具监测系统[J]，机械工程学报：1991(10)：7-11.
[18]Kristo, sheng Huang, et,at. Detecting tool breakage using accelerometer in ball-nose end milling[C].10th. Intl Conf. on Automation Robotics and Vision.2008,12:17-21.
[19]曹伟青.B样条模糊神经网络在刀具故障诊断中的应用[D].西南交通大学硕士研究生学位论文,2005.12：18-26.
[20]刘志艳等.刀具破损在线监测及其系统的研究[J].燕山大学学报,1998,4：127-128.
[21]Tamas Szecsi, A DC motor based cutting tool condition monitoring system[J], Journal of Materials Processing Technology,1999,92:350-354.
[22]Luis Alfonso Franco-Gasca, Gilberto Herrera-Ruiz, Rocio Peniche-Vera, Rene de Jesus Romero-Troncoso, Wbaldo Leal-Tafolla. Sensorless tool failure monitoring system for drilling machines[J]. International Journal of Machine Tools & Manufacture,2006, 46:381-386.
[23]Li Xiaoli, Ouyang Gaoxiang, Liang Zhenhu. Complexity measure of motor current signals for tool flute breakage detection in end milling[J]. International Journal of Machine Tools & Manufacture,2008,48:371-379.
[24]徐顺利等.用切削功率进行刀具磨损在线监测研究[J].轴承,1995(8)：16-18.
[25]甘启义等.机床功率监控技术中一种新的监控特征量[J].组合机床与自动化加工技术,1992,10：20-22.
[26]Axinte D, Gindy N, Fox K, Unanue. Process monitoring to assist the workpiece surface quality in machining[J]. International Journal of Machine Tools and Manufacture,2004, 44:1091-1098.
[27]梁德沛,李宝丽.机械工程参量的动态测量技术[M],北京：机械工业出版社,1995：168-177.
[28]秦自楷.压电石英晶体[M].第一版,北京：国防工业出版社,1980.
[29]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.
[30]Kim J-D, Kim D-S. Development of a combined type tool dynamometer with a piezo-film cccelerometer for an ultra-precision lathe [J].Journal of Materials Processing Technology, 1997,71:360-366.
[31]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,1995(5)：3-7.
[32]唐偃生,韩永澎.GH-H实体压磁式测力仪的研制与应用[J].工业计量,2002(5)：41-42.
[33]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.
[34]Martin B. Jun. O. Burak Ozdoganlar, Andreas Kirchheim,et al. Evaluation of a spindle-based force sensor for monitoring and fault diagnosis of machining operations[J]. International Journal of Machine Tools & Manufacture 42 (2002) 741-751.
[35]刘晓玲.新型压电动态切削测力系统的结构设汁与优化分析[D].大连：大连理工大学,2005.03.
[36]卢江月.三向压电式车削测力系统的研制[D].大连：大连理工大学,2008.12.
[37]张铁.三向压电式车削测力系统的性能研究与结构设计[D].大连：大连理工大学,2007.12.
[38]卢江跃,孙宝元,张军,等.YDC—11189车削测力系统性能改进研究[J].传感器与微系统,2009,28(6)：22-24.
[39]谢印国.高能材料HEM切削力测试系统的研制[D].大连：大连理工大学,2007.12.
[40]韩丽丽,孙宝元,钱敏.新型压电三向钻削测力系统的设计与实验研究[J].压电与声光,2007,29(3)：283-289.
[41]W Morey, G. Meltz, W H Glenn. Fiber potic bragg grating sensors. Pr oc SPI E.1989, 1169: 98-107.
[42]姜德生,何伟.光纤光栅传感器的应用概况.[J]光电子激光.2002,13(4)：420-430.
[43]姜德生,梁磊等.光纤光栅传感技术在重大工程结构监测中的应用[C].2001年国家自然科基金委员会重大工程灾变行为与健康监测学术研讨会.
[44]刘胜春,姜德生等.光纤光栅测力传感器的研究及应用.[J]武汉理工大学学报.2006,30(2)：209-211.
[45]南秋明.光纤光栅测力环在悬索桥索力监测中应用.[J]公路交通科技.2010,27(3)：64-68.
[46]Suresh R, Tjin S C Ngo NQ. Shear force sensing by strain transformation using non-rectilinearly embedded fiber bragg grating[J]. Sensors and Actuators A:Physical.2004, 116:(1) 107-118.
[47]张伟刚,李红民,开桂云等.轮辐式温度自动补偿型光纤光栅测力传感器.[J]中国激光.2005,32(7)：957-960.
[48]刘兆妍,雷震山.应用光纤光栅和虚拟仪器的切削力测量技术[J].大连理工大学学报,2005,39(10)：53-55.
[49]李宏男,任亮等.结构健康检测光纤光栅传感技术[M].北京：中国建筑工业出版社,2008
[50]Mousumi M, Tarun K G, Ashim K C. et al. Fibre bragg gratings in structural health monitoring-present status and applications[J]. Sensors and Actuators A 147 (2008) 150-164.
[50]周建华.光纤光栅传感器应变传递特性研究[D].武汉：武汉理工大学,2010.05.
[51]赵芝眉.电阻应变片式测力仪布片方法的讨论[J].南京工学院学报,1980,3：87-99.
[52]王娟.三维动态切削测力仪结构参数优化[D].北京：北方工业大学,2009.05.
[53]袁哲俊.电阻应变片式测力仪设计中几个问题的探讨[D].哈尔滨工业大学,1979.
[54]陶晓亮.基于光纤Bragg光栅传感的车削力测量系统研究[D].武汉：武汉理工大学,2011.05.
[55]沙俊.新型铣削测力仪[D].机械工程师,1987,4：34-36.
[56]阮鸿雁,王勇.加长八角环测力系统的优化设计[J].江苏工学院学报,1985,1：76-87.
[57]邓平凡ANSYS有限元自学手册[M].北京：人民邮电出版社,2007.
[58]张志涌,徐彦琴MATLAB教程—基于6.X版本[M].北京：北京航空航天出版社,2001.