花岗石薄型板材高效加工关键技术与锯解设备设计研究
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摘要
花岗石薄型板材因薄而降低生产成本以及装饰成本,同时可以节约和有效利用有限的石材资源,因此幅面宽度在600mm-1000mm的花岗石薄型板材的生产加工引起了越来越多的重视。但是目前薄型板材的加工生产效率低,表面质量差,刀具寿命低,严重制约了薄型板材的大批量应用和生产。
通过比较目前花岗石薄型板材加工方法的优劣性,分析锯解和研磨过程中制约生产率以及加工质量的关键性技术问题,进而针对以上问题对锯解以及研磨装备进行规划,重点对与加工质量和加工效率密切相关的轴向力以及研磨轨迹进行分析。探讨锯解过程中由于锯片的动态不稳定性引发的轴向力以及轴向位移的计算,通过模态分析研究锯片的厚度、夹紧比、转速以及直径对锯片动态性能的影响；研究正确的组织研磨过程所必须遵守的原则,优化研磨运动轨迹；对薄型板材加工过程中存在的临界经济厚度进行初步讨论。考虑花岗石薄型板材高效加工过程的特殊性,制定锯解设备的设计指标,结合模块化设计技术以及三维仿真技术进行设备的开发和优化,对设备的导向支承横梁模块、主轴模块等关键结构进行重点设计。
借助有限元分析软件,对用于本课题中大幅面花岗石薄型板材加工的1600mm的薄型金刚石圆锯片在高效加工参数组合下进行仿真分析,即锯切线速度为80m／s,进给速度为0.8m／min,锯切深度为20mm。通过静态分析和有预应力的模态分析验证其在高效加工参数下锯解的静、动性能；通过热应力耦合验证其热态性能；通过非线性屈曲分析计算薄型锯片的临界载荷。利用Matlab优化工具箱对主轴模块中的主轴单元以许用扭转变形角、许用偏转角、许用切应力为约束条件,以轴端变形挠度和质量为目标函数,取主轴的直径、跨距以及外伸端长度为设计变量对主轴进行多目标优化,优化结果表明在主轴直径为90mm、外伸端长度为50m、轴承跨距为350mm的情况下,主轴的经济综合性能与使用性能达到最佳的组合。
本课题的研究旨在降低生产成本、提高加工效率,因此,其研究成果对我国薄型板材的生产加工具有现实的指导意义；同时,课题的研究思路和研究方法对薄型、超薄型板材加工的理论研究也将产生深远影响。
本文得到山东省自然科学基金资助(项目编号：Z2007F07)。
Granite thin slab reduce production cost and adornment cost because of its thickness, at the same time can economical and effective utilization of the precious stone resources, so the process of granite thin slab whose width between 600mm and 1000mm attracted more and more attention. At present the process efficiency of thin slab is low, surface quality is poor, the tool life is short, and have already seriously restricted the mass production and application.
For the above problems, the paper compared different processes of granite thin slab, analyzed the key technology associated with production efficiency and processing quality during saw and grind. Then planed the saw and grind equipment, researched the axial force and grinding trajectory, calculated the axial force and displacement caused by dynamic instability of the disc. By means of modal analysis, investigated the influence of parameters such as thickness, clamping ratio, rotating speed and diameter to dynamic performance. Proposed the correct principle during grinding and optimized the grind trajectory, investigated the critical economic thickness of granite thin slab. Considering the specificity of granite thin slab efficient processing, formulated the design index, developed and optimized the saw equipment based on modular design technology and 3d simulation technology, studied emphatically on the key structure such as beam unit and spindle unit.
Simulation analyzed the performance of diamond circular thin disc under efficient processing parameters based on Finite Element software, the diameter of disc was 1600mm, the cutting speed was 80m/s, the feeding speed was 0.8mm/min and the cutting depth was 20mm. Tested comprehensive performance by static analysis, modal analysis under prestress and thermal-stress analysis, calculated the critical load of thin disc through buckling analysis, verified the parameters and the performance of thin disc were credible. Optimized the spindle unit based on matlab optimization toolbox in multi-objective function optimization, the optimization constraints were allowable torsion deflection angle, allowable deflection angle, and allowable stress, the objective function were stiffness and quality, the design variables were the central hole diameter, the span, and the overhanging length of spindle. The result showed the comprehensive performance of the spindle after optimization is better, when the central hole diameter was 90mm, the overhanging length was 50mm, the span was 350mm.
The purpose of the paper are lower production costs, improve the processing efficiency, so the academic achievements can provide practical guidance for the process of thin slab. At the same time the Research ideas and research methods have a far-reaching influence on the theoretical investigation of thin and ultrathin slab processing.
The paper is supported by Natural Science Foundation of Shandong Province (Z2007F07).
通过比较目前花岗石薄型板材加工方法的优劣性,分析锯解和研磨过程中制约生产率以及加工质量的关键性技术问题,进而针对以上问题对锯解以及研磨装备进行规划,重点对与加工质量和加工效率密切相关的轴向力以及研磨轨迹进行分析。探讨锯解过程中由于锯片的动态不稳定性引发的轴向力以及轴向位移的计算,通过模态分析研究锯片的厚度、夹紧比、转速以及直径对锯片动态性能的影响；研究正确的组织研磨过程所必须遵守的原则,优化研磨运动轨迹；对薄型板材加工过程中存在的临界经济厚度进行初步讨论。考虑花岗石薄型板材高效加工过程的特殊性,制定锯解设备的设计指标,结合模块化设计技术以及三维仿真技术进行设备的开发和优化,对设备的导向支承横梁模块、主轴模块等关键结构进行重点设计。
借助有限元分析软件,对用于本课题中大幅面花岗石薄型板材加工的1600mm的薄型金刚石圆锯片在高效加工参数组合下进行仿真分析,即锯切线速度为80m／s,进给速度为0.8m／min,锯切深度为20mm。通过静态分析和有预应力的模态分析验证其在高效加工参数下锯解的静、动性能；通过热应力耦合验证其热态性能；通过非线性屈曲分析计算薄型锯片的临界载荷。利用Matlab优化工具箱对主轴模块中的主轴单元以许用扭转变形角、许用偏转角、许用切应力为约束条件,以轴端变形挠度和质量为目标函数,取主轴的直径、跨距以及外伸端长度为设计变量对主轴进行多目标优化,优化结果表明在主轴直径为90mm、外伸端长度为50m、轴承跨距为350mm的情况下,主轴的经济综合性能与使用性能达到最佳的组合。
本课题的研究旨在降低生产成本、提高加工效率,因此,其研究成果对我国薄型板材的生产加工具有现实的指导意义；同时,课题的研究思路和研究方法对薄型、超薄型板材加工的理论研究也将产生深远影响。
本文得到山东省自然科学基金资助(项目编号：Z2007F07)。
Granite thin slab reduce production cost and adornment cost because of its thickness, at the same time can economical and effective utilization of the precious stone resources, so the process of granite thin slab whose width between 600mm and 1000mm attracted more and more attention. At present the process efficiency of thin slab is low, surface quality is poor, the tool life is short, and have already seriously restricted the mass production and application.
For the above problems, the paper compared different processes of granite thin slab, analyzed the key technology associated with production efficiency and processing quality during saw and grind. Then planed the saw and grind equipment, researched the axial force and grinding trajectory, calculated the axial force and displacement caused by dynamic instability of the disc. By means of modal analysis, investigated the influence of parameters such as thickness, clamping ratio, rotating speed and diameter to dynamic performance. Proposed the correct principle during grinding and optimized the grind trajectory, investigated the critical economic thickness of granite thin slab. Considering the specificity of granite thin slab efficient processing, formulated the design index, developed and optimized the saw equipment based on modular design technology and 3d simulation technology, studied emphatically on the key structure such as beam unit and spindle unit.
Simulation analyzed the performance of diamond circular thin disc under efficient processing parameters based on Finite Element software, the diameter of disc was 1600mm, the cutting speed was 80m/s, the feeding speed was 0.8mm/min and the cutting depth was 20mm. Tested comprehensive performance by static analysis, modal analysis under prestress and thermal-stress analysis, calculated the critical load of thin disc through buckling analysis, verified the parameters and the performance of thin disc were credible. Optimized the spindle unit based on matlab optimization toolbox in multi-objective function optimization, the optimization constraints were allowable torsion deflection angle, allowable deflection angle, and allowable stress, the objective function were stiffness and quality, the design variables were the central hole diameter, the span, and the overhanging length of spindle. The result showed the comprehensive performance of the spindle after optimization is better, when the central hole diameter was 90mm, the overhanging length was 50mm, the span was 350mm.
The purpose of the paper are lower production costs, improve the processing efficiency, so the academic achievements can provide practical guidance for the process of thin slab. At the same time the Research ideas and research methods have a far-reaching influence on the theoretical investigation of thin and ultrathin slab processing.
The paper is supported by Natural Science Foundation of Shandong Province (Z2007F07).
引文
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[2]张进生,王学哲,王日君,等.花岗石精密平台与构件制品高效加工技术与设备开发[J].石材.2006,(1)：6-9
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