电流变材料在车削颤振抑制中的应用及理论研究
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摘要
机械制造过程中的切削颤振是影响产品质量和妨碍工厂自动化的一个重要因素，对其进行在线监视和控制成为改善切削系统稳定性的一项关键性实用技术。本论文将电流变技术应用到车削颤振的控制中，取得了令人满意的效果。论文的主要工作如下：
(1)针对细长轴工件切削加工中的切削振动特点，应用电流变材料设计了一种基于智能电流变液阻尼器的切削颤振抑制结构和一种基于电流变液双电极复合结构的颤振抑制装置。通过静加载实验和激振实验分别对它们在不同电场强度下的静态特性和动态特性进行了研究，建立了相关的理论模型，进行了颤振抑制的理论研究。在此基础上，将两种结构成功应用于不同电场强度，不同切削条件、不同工件材料下的细长轴工件的端面车削和切断加工颤振抑制，而且工件表面质量有很大改善，但相同条件下两种结构的实验结果不尽相同。
(2)为了保证电流变液切削颤振抑制结构及装置的电控性能稳定，对电流变材料的成分选用、影响因素、稳定性和电流变效应等进行了实验和理论研究。开发了一种分散稳定性好，电流变效应指标可以同在售商品相媲美，成本低廉，环保型的高性能电流变材料。
(3)建立了基于智能电流变阻尼器的切削颤振抑制结构作用下的切削系统的数学模型，对其颤振抑制作用原理进行了深入的理论分析，并给出了切削颤振抑制结构作用的条件。
(4)应用集中参数法对电流变液双电极复合结构颤振抑制装置作用下的切削系统进行了简化，建立了系统的粘—弹塑性模型，对装置的颤振抑制作用进行了深入的理论分析，并提出了此种装置的颤振抑制条件和相应的改进措施。
(5)讨论了各种颤振的产生机理、特征参数和稳定条件。基于对细长轴工件切削过程动态切削力和再生颤振效应的理论分析，对整个切削系统特性进行了理论和实验研究，建立了两自由度模型，讨论了切削加工系统的稳定条件和颤振形态；模拟细长轴工件实际切削过程，进行了两种电流变液结构作用下的切削系统的动态特性激振实验，建立了结构作用下的两自由度系统模型，探讨了结构的颤振抑制规律，并对结构的颤振抑制实验结果进行了理论解释。
Cutting chatter during machining process is one of the important factors influence quality of products and obstacle to factory automation. Therefore, the chatter online monitoring and control are to be key art to improve the stability of machining process. This dissertation applied electrorheological (ER) technology in machining chatter control, and results were satisfied and innovative.
First, one kind of damp tunable chatter suppression equipment based on ER fluids double electrodes composite structure and one kind of frequency tunable cutting chatter suppression structure based on intelligent ER fluids damper were designed to the vibration characteristics of slender parts machining.. The rules of their static and dynamic properties under different electric fields were tested through static loading tests and excitation tests respectively. Related theoretic models were established to study how to realize chatter suppression through changes of structure stiffness and damp of cutting system under this two ERF structures. And the two structures were applied in chatter suppression of turning successfully. This dissertation carried out a series of experiment under different cutting conditions and different materials of workpieces with different electric fields added on this two structures, all the experiment results showed that this two kinds of chatter suppression ERF structure can not only con
trol the chatter in turning operation efficiently, but can improve the surface quality of the workpiece, and got different results with same conditions under the two structures.
Secondly, composition selection, influence factors, stability, electrorheological effect and so on properties of ER material were studied through theoretic discussion and experiments to ensure electric control properties of ERF chatter suppression structure and equipment stable. And one kind of advanced ERF was developed, which has excellent stability, low cost, environmental protection, and all kinds of ER effect indexes are near to or better than present products selling now.
Thirdly, chatter suppression function of the chatter suppression structure of ERF damper were analyzed thoroughly theoretically with mathematical model established and chatter suppression function conditions of the structure were analyzed.
Fourthly, chatter suppression function of the chatter suppression equipment of the ERF double electrodes composite structure were analyzed thoroughly theoretically with viscidity- elasticity plastical mathematical model established and charter suppression function conditions of the equipment were given, so were corresponding improvement measures.
Finally, based on mechanism analysis of all kinds of chatters, this dissertation discussed their recognition characteristic parameters and stable conditions of corresponding cutting systems. With theoretic study of dynamic force and regenerative chatter during machining process of slender parts, this dissertation carried out theoretic study and
experiment analysises of the whole cutting system, established a two freedoms model of the cutting system, discussed its stable conditions and chatter type. With experiments simulating system property of practical cutting process, this dissertation carried out excitation tests of cutting system under former two kinds ERF structures, established
their two freedoms system model, discussed their chatter suppression function rules respectively, explained their chatter suppression results respectively.
(1)针对细长轴工件切削加工中的切削振动特点，应用电流变材料设计了一种基于智能电流变液阻尼器的切削颤振抑制结构和一种基于电流变液双电极复合结构的颤振抑制装置。通过静加载实验和激振实验分别对它们在不同电场强度下的静态特性和动态特性进行了研究，建立了相关的理论模型，进行了颤振抑制的理论研究。在此基础上，将两种结构成功应用于不同电场强度，不同切削条件、不同工件材料下的细长轴工件的端面车削和切断加工颤振抑制，而且工件表面质量有很大改善，但相同条件下两种结构的实验结果不尽相同。
(2)为了保证电流变液切削颤振抑制结构及装置的电控性能稳定，对电流变材料的成分选用、影响因素、稳定性和电流变效应等进行了实验和理论研究。开发了一种分散稳定性好，电流变效应指标可以同在售商品相媲美，成本低廉，环保型的高性能电流变材料。
(3)建立了基于智能电流变阻尼器的切削颤振抑制结构作用下的切削系统的数学模型，对其颤振抑制作用原理进行了深入的理论分析，并给出了切削颤振抑制结构作用的条件。
(4)应用集中参数法对电流变液双电极复合结构颤振抑制装置作用下的切削系统进行了简化，建立了系统的粘—弹塑性模型，对装置的颤振抑制作用进行了深入的理论分析，并提出了此种装置的颤振抑制条件和相应的改进措施。
(5)讨论了各种颤振的产生机理、特征参数和稳定条件。基于对细长轴工件切削过程动态切削力和再生颤振效应的理论分析，对整个切削系统特性进行了理论和实验研究，建立了两自由度模型，讨论了切削加工系统的稳定条件和颤振形态；模拟细长轴工件实际切削过程，进行了两种电流变液结构作用下的切削系统的动态特性激振实验，建立了结构作用下的两自由度系统模型，探讨了结构的颤振抑制规律，并对结构的颤振抑制实验结果进行了理论解释。
Cutting chatter during machining process is one of the important factors influence quality of products and obstacle to factory automation. Therefore, the chatter online monitoring and control are to be key art to improve the stability of machining process. This dissertation applied electrorheological (ER) technology in machining chatter control, and results were satisfied and innovative.
First, one kind of damp tunable chatter suppression equipment based on ER fluids double electrodes composite structure and one kind of frequency tunable cutting chatter suppression structure based on intelligent ER fluids damper were designed to the vibration characteristics of slender parts machining.. The rules of their static and dynamic properties under different electric fields were tested through static loading tests and excitation tests respectively. Related theoretic models were established to study how to realize chatter suppression through changes of structure stiffness and damp of cutting system under this two ERF structures. And the two structures were applied in chatter suppression of turning successfully. This dissertation carried out a series of experiment under different cutting conditions and different materials of workpieces with different electric fields added on this two structures, all the experiment results showed that this two kinds of chatter suppression ERF structure can not only con
trol the chatter in turning operation efficiently, but can improve the surface quality of the workpiece, and got different results with same conditions under the two structures.
Secondly, composition selection, influence factors, stability, electrorheological effect and so on properties of ER material were studied through theoretic discussion and experiments to ensure electric control properties of ERF chatter suppression structure and equipment stable. And one kind of advanced ERF was developed, which has excellent stability, low cost, environmental protection, and all kinds of ER effect indexes are near to or better than present products selling now.
Thirdly, chatter suppression function of the chatter suppression structure of ERF damper were analyzed thoroughly theoretically with mathematical model established and chatter suppression function conditions of the structure were analyzed.
Fourthly, chatter suppression function of the chatter suppression equipment of the ERF double electrodes composite structure were analyzed thoroughly theoretically with viscidity- elasticity plastical mathematical model established and charter suppression function conditions of the equipment were given, so were corresponding improvement measures.
Finally, based on mechanism analysis of all kinds of chatters, this dissertation discussed their recognition characteristic parameters and stable conditions of corresponding cutting systems. With theoretic study of dynamic force and regenerative chatter during machining process of slender parts, this dissertation carried out theoretic study and
experiment analysises of the whole cutting system, established a two freedoms model of the cutting system, discussed its stable conditions and chatter type. With experiments simulating system property of practical cutting process, this dissertation carried out excitation tests of cutting system under former two kinds ERF structures, established
their two freedoms system model, discussed their chatter suppression function rules respectively, explained their chatter suppression results respectively.
引文
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