微小型机床的结构参数优化及动态特性分析
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摘要
随着科技的发展当今社会对微小型零件的需求逐渐增加,微小型机床也因其与被加工零件尺寸匹配度好、能耗小、节省空间以及便于装配和运输等诸多优点而深受人们普遍关注,微小型机床的动态特性对加工精度和表面粗糙度有很大的影响,因此对微小型机床进行动态特性分析和结构参数优化对提高加工精度降低表面粗糙度具有重要的意义。
首先,对微小型机床的关键部件空气主轴进行了流体动力学分析,对空气主轴气膜压力分布进行仿真模拟得出不同偏心率下的承载力和刚度,并对主轴进行了静力学分析研究主轴在不同切削力下的变形,得出主轴的磨损并非由刚度不足所引起。在上述分析的基础上对空气主轴进行了动力学分析,得出主轴的磨损出现在三阶固有频率附近。
其次,运用刚度等效原则建立了微小型机床的有限元模型,对其进行动力学分析,得出床身刚度是整个机床的薄弱环节,并采用了多点锤击单点响应的方法对机床整体和床身进行了动态测试,得出了机床整体及床身的固有频率及其相应的振型,把理论计算结果和实际测试数据进行比较,验证了有限元模型的合理性。
最后,在保证床身质量不变的前提下通过对床身进行结构设计和尺寸优化,得到床身的造型和尺寸参数,有效提高了床身的动力学特性。
With the technology development,more and more miniature parts were demanded in nowadays, and lots people pay close attention to micro machine tool due to its good size matching with workpiece, low energy consumption, save space, and easy to assemble and transport. The dynamic characteristic of the micro machine has an important influence to the precision and surface roughness. Therefore, dynamic analysis and structural optimization of the micro machine can improve the precision and cut down the surface roughness.
Firstly, fluid dynamics analysis carried out on the air spindle obtained the bearing capacity and rigidity under different eccentricity,then static analysis of the air spindle was done, researched the deformation under different cutting force, found the spindle wear not caused by lack of rigidity. At last the dynamic analysis of the air spindle were carried out, and found that the spindle wear occurred in the third-order natural frequency.
Secondly, the principle of equivalent stiffness was used to establish the finite element model of the micro machine. After the dynamic analysis, it was found that the airframe was the weak part of the machine. By using the transient powering method and the method of multipoint hammering and single point response, inherent frequency and the corresponding mode of vibration are educed. The theoretical results and actual test data are compared to verify the accuracy of the finite element model.
Finally, without changing the weight of the airframe by using the structural design and optimization, improved the dynamics of the machine tool.
首先,对微小型机床的关键部件空气主轴进行了流体动力学分析,对空气主轴气膜压力分布进行仿真模拟得出不同偏心率下的承载力和刚度,并对主轴进行了静力学分析研究主轴在不同切削力下的变形,得出主轴的磨损并非由刚度不足所引起。在上述分析的基础上对空气主轴进行了动力学分析,得出主轴的磨损出现在三阶固有频率附近。
其次,运用刚度等效原则建立了微小型机床的有限元模型,对其进行动力学分析,得出床身刚度是整个机床的薄弱环节,并采用了多点锤击单点响应的方法对机床整体和床身进行了动态测试,得出了机床整体及床身的固有频率及其相应的振型,把理论计算结果和实际测试数据进行比较,验证了有限元模型的合理性。
最后,在保证床身质量不变的前提下通过对床身进行结构设计和尺寸优化,得到床身的造型和尺寸参数,有效提高了床身的动力学特性。
With the technology development,more and more miniature parts were demanded in nowadays, and lots people pay close attention to micro machine tool due to its good size matching with workpiece, low energy consumption, save space, and easy to assemble and transport. The dynamic characteristic of the micro machine has an important influence to the precision and surface roughness. Therefore, dynamic analysis and structural optimization of the micro machine can improve the precision and cut down the surface roughness.
Firstly, fluid dynamics analysis carried out on the air spindle obtained the bearing capacity and rigidity under different eccentricity,then static analysis of the air spindle was done, researched the deformation under different cutting force, found the spindle wear not caused by lack of rigidity. At last the dynamic analysis of the air spindle were carried out, and found that the spindle wear occurred in the third-order natural frequency.
Secondly, the principle of equivalent stiffness was used to establish the finite element model of the micro machine. After the dynamic analysis, it was found that the airframe was the weak part of the machine. By using the transient powering method and the method of multipoint hammering and single point response, inherent frequency and the corresponding mode of vibration are educed. The theoretical results and actual test data are compared to verify the accuracy of the finite element model.
Finally, without changing the weight of the airframe by using the structural design and optimization, improved the dynamics of the machine tool.
引文
1庞滔.超精密加工技术.国防工业出版社, 2000:1~7
2毛瑞生.台式五轴联动超精密数控铣床的总体设计.哈尔滨工业大学硕士论文. 2006:2~9
3孙雅洲,梁迎春,程凯.微米和中间尺度机械制造.机械工程学报. 2004, 40(5):1~6
4闻邦椿.产品的全功能与全性能的综合设计.机械工业出版社. 2008:1~2
5金明刚.高速电主轴设计与动静态特性分析.吉林大学硕士学位论文. 2009:4~7
6段明亮.空气静压电主轴静态及热态性能的有限元耦合分析及实验研究.广州工业大学硕士学位论文. 2006:5~9
7 T. A. Dow, E. L. Miller, K. Garrard. Tool Force and Deflection Compensation for Small Milling Tools. Precision Engineering. 2004,(28):31~45
8 W. Y. Bao, I. N. Tansel. Modeling Micro-end-milling Operations: Part II. Tool run-out. International Journal of Machine Tools & Manufacture. 2000,(40):2175~2192
9 Q. S. Ba, K. Yang, Y. C. Liang, C. L. Yang, B. Wang. Tool Run-out Effects on Wear and Mechanics Behavior in Micro-end Milling. American Vacuum Society. 2009:1566~1572
10 L. Uriarte, A. Herrero, M. Zatarain, et al. Error Budget and Stiffness Chain Assessment in a Micro-milling Machine Equipped with Tools Less Than 0.3 mm in Diameter. Precision Engineering. 2007,(3):1~12
11 Alting L, Kimura F, Hansen HN, Bissaco G. Micro engineering. Keynote paper. Ann CIRP 2003,52(2):1~24
12粟时平,李圣怡,王贵林.基于空间误差模型的加工中心几何误差辨识方法.机械工程学报. 2002,38(7):121~125
13赵宏林,吴智恒,贺艳苓,刘忠,刘学杰.结合部特性参数及其在机床结构建模中的融合技术.设计与研究. 2007,(5):51~54
14 Y M Huang, W P Fu, J X Tong. Analysis for Acquiring Method of Applied Nodal Damping Parameters of Joint Surfaces. AMSE, Periodical, MODLELLING, MEASUREMENT&CONTROL, B, 1992,46(3):35~40
15王效岳,华珍.机床整机刚度的建模及试验分析. Mechanical Science and Technology. 1996:964~966
16范晋伟,陈文,杨万然,朱晓勇.基于多学科设计优化的数控机床综合误差补偿.机械设计与制造. 2008:152~154
17 H. Shinno, H. Hashizume, Y. Ito, C. Sato, Structural Configuration and Performances of Machining Environment-controlled Ultra Precision diamond turning Machine‘capsule’, Ann. CIRP. 1992, 41(2): 425~428
18戴磊,关镇群,单菊林,牛聪民等.机床结构三维参数化形状优化设计.机械工程学报. 2008, 44(5):152~159
19翟有新.平台式惯导系统抗振稳定性研究.西安交通大学博士论文. 1999:1~4
20张阿舟,诸得超等.实用振动工程,振动控制与设计.航空工业出版社, 1997:1~20, 321~327, 650~925
21 Rajagopal Karpurapu, Bathust R J. Development of a Finite Element Analysis Postprocessing Program. Advances in Engineering Software. 1993:1~6
22 J. Robert, Melish. Finite Element Analysis of Automobile Structure. SAE740319, 1974: 2~7
23 D. Radaj, A, Zimmer, H. Geisler. Finite Element Analysis, an Automobile Engineer’s Tool Structure, SAE 740319. 1974:1~4
24 R Champion, M Ensminger. Finite Element Analysis with Personal Computer. New York, Marcel Dekker. 1988:17~28
25 Zienkiewicz OC. The Finite Element Method. London, McGraw-Hill, 1977:20~22
26 FMC公司.有限元在振动机械上的应用. ANSYS China Users Conference
27 Proceedings. 1996:303~306
28 Ibrahim S R. Modal Identification Techniques Assessment and Comparison. Proc. of 3rd IMAC, 1985:831~839
29周汉辉.数控机床精度检测项目及常用工具.技术市场. 1999(6):55~57
30 J M Lweridan, D L Brown,R J Allemang. Time Dimain Parameter Identification Methods for Linear Modal Analysis: A Unifying Approach. J. of Vibration, Acoustics, Stress, and Reliability in design. 1986,108:1~8
31高品贤.振动、冲击与噪声测试技术.西南交通大学出版社. 1992:13~17
32吕江涛. SX360型自卸车车架静、动态有限元分析及结构改进西安理工大学硕士学位论文. 2000:2
33 Eermann H J. Static Analysis of Commercial Vehicle Frames: A Hybird-Finite Element and Analytical-Method. lnt. J. of Vehicle Design, 1984:2~5
34崔俊之,梁俊.现代有限元软件方法.国防工业出版社, 1995:1~2
35 K. Q. Xu. Frequency Domain Modal Parameters Identification of High Order Systems in a Numerically Stale Way, ASME Journal of Vibration and Acoustics. 1997:265~270
36管迪华.模态分析技术.清华大学出版社,1996:12~15
37周磊,陈时锦,梁迎春,程凯.基于失效树分析的机床进给系统可靠性设计.机械设计与制造. 2007(6):60~62
38张霖,赵东标.基于损失模型的三轴小型超精密铣床结构设计参数优化分析.机械科学与技术. 2007,26(5):548~551
39 Mishima N, Kousuke I. Robustness Evaluation of a Miniaturized Machine Tool. 25 th Design Automation Conference[C ]. 1999
40 X. C. Luo, K. Cheng, D. Webb, F. Wardle. Design of Ultra Precision Machine Tools with Applications to Manufacture of Miniature and Micro Components. Journal of Materials Processing Technology. 2005, (167):515~528
41 HR8 Ultrasonic Motor User Manual. Nan motion Data Systems Inc.2005
42雷尼绍RG2直线光栅编码器系统.北京元茂兴. 2005:2~7
43机械装着用モ〡タ&スピンドル. NSK Nakanishi Inc. 2004:2~41
44曹树谦,张文谦等.振动结构模态分析(理论、实验与应用).天津大学出版社, 2002:1~3, 17~27
45 J N Juang, Pappa R. An Eigensystem Realization Algorithm for Modal Parameter Identification and Model Reduction. J. of Guidance, Control and Dynamics, 1985:620~627
2毛瑞生.台式五轴联动超精密数控铣床的总体设计.哈尔滨工业大学硕士论文. 2006:2~9
3孙雅洲,梁迎春,程凯.微米和中间尺度机械制造.机械工程学报. 2004, 40(5):1~6
4闻邦椿.产品的全功能与全性能的综合设计.机械工业出版社. 2008:1~2
5金明刚.高速电主轴设计与动静态特性分析.吉林大学硕士学位论文. 2009:4~7
6段明亮.空气静压电主轴静态及热态性能的有限元耦合分析及实验研究.广州工业大学硕士学位论文. 2006:5~9
7 T. A. Dow, E. L. Miller, K. Garrard. Tool Force and Deflection Compensation for Small Milling Tools. Precision Engineering. 2004,(28):31~45
8 W. Y. Bao, I. N. Tansel. Modeling Micro-end-milling Operations: Part II. Tool run-out. International Journal of Machine Tools & Manufacture. 2000,(40):2175~2192
9 Q. S. Ba, K. Yang, Y. C. Liang, C. L. Yang, B. Wang. Tool Run-out Effects on Wear and Mechanics Behavior in Micro-end Milling. American Vacuum Society. 2009:1566~1572
10 L. Uriarte, A. Herrero, M. Zatarain, et al. Error Budget and Stiffness Chain Assessment in a Micro-milling Machine Equipped with Tools Less Than 0.3 mm in Diameter. Precision Engineering. 2007,(3):1~12
11 Alting L, Kimura F, Hansen HN, Bissaco G. Micro engineering. Keynote paper. Ann CIRP 2003,52(2):1~24
12粟时平,李圣怡,王贵林.基于空间误差模型的加工中心几何误差辨识方法.机械工程学报. 2002,38(7):121~125
13赵宏林,吴智恒,贺艳苓,刘忠,刘学杰.结合部特性参数及其在机床结构建模中的融合技术.设计与研究. 2007,(5):51~54
14 Y M Huang, W P Fu, J X Tong. Analysis for Acquiring Method of Applied Nodal Damping Parameters of Joint Surfaces. AMSE, Periodical, MODLELLING, MEASUREMENT&CONTROL, B, 1992,46(3):35~40
15王效岳,华珍.机床整机刚度的建模及试验分析. Mechanical Science and Technology. 1996:964~966
16范晋伟,陈文,杨万然,朱晓勇.基于多学科设计优化的数控机床综合误差补偿.机械设计与制造. 2008:152~154
17 H. Shinno, H. Hashizume, Y. Ito, C. Sato, Structural Configuration and Performances of Machining Environment-controlled Ultra Precision diamond turning Machine‘capsule’, Ann. CIRP. 1992, 41(2): 425~428
18戴磊,关镇群,单菊林,牛聪民等.机床结构三维参数化形状优化设计.机械工程学报. 2008, 44(5):152~159
19翟有新.平台式惯导系统抗振稳定性研究.西安交通大学博士论文. 1999:1~4
20张阿舟,诸得超等.实用振动工程,振动控制与设计.航空工业出版社, 1997:1~20, 321~327, 650~925
21 Rajagopal Karpurapu, Bathust R J. Development of a Finite Element Analysis Postprocessing Program. Advances in Engineering Software. 1993:1~6
22 J. Robert, Melish. Finite Element Analysis of Automobile Structure. SAE740319, 1974: 2~7
23 D. Radaj, A, Zimmer, H. Geisler. Finite Element Analysis, an Automobile Engineer’s Tool Structure, SAE 740319. 1974:1~4
24 R Champion, M Ensminger. Finite Element Analysis with Personal Computer. New York, Marcel Dekker. 1988:17~28
25 Zienkiewicz OC. The Finite Element Method. London, McGraw-Hill, 1977:20~22
26 FMC公司.有限元在振动机械上的应用. ANSYS China Users Conference
27 Proceedings. 1996:303~306
28 Ibrahim S R. Modal Identification Techniques Assessment and Comparison. Proc. of 3rd IMAC, 1985:831~839
29周汉辉.数控机床精度检测项目及常用工具.技术市场. 1999(6):55~57
30 J M Lweridan, D L Brown,R J Allemang. Time Dimain Parameter Identification Methods for Linear Modal Analysis: A Unifying Approach. J. of Vibration, Acoustics, Stress, and Reliability in design. 1986,108:1~8
31高品贤.振动、冲击与噪声测试技术.西南交通大学出版社. 1992:13~17
32吕江涛. SX360型自卸车车架静、动态有限元分析及结构改进西安理工大学硕士学位论文. 2000:2
33 Eermann H J. Static Analysis of Commercial Vehicle Frames: A Hybird-Finite Element and Analytical-Method. lnt. J. of Vehicle Design, 1984:2~5
34崔俊之,梁俊.现代有限元软件方法.国防工业出版社, 1995:1~2
35 K. Q. Xu. Frequency Domain Modal Parameters Identification of High Order Systems in a Numerically Stale Way, ASME Journal of Vibration and Acoustics. 1997:265~270
36管迪华.模态分析技术.清华大学出版社,1996:12~15
37周磊,陈时锦,梁迎春,程凯.基于失效树分析的机床进给系统可靠性设计.机械设计与制造. 2007(6):60~62
38张霖,赵东标.基于损失模型的三轴小型超精密铣床结构设计参数优化分析.机械科学与技术. 2007,26(5):548~551
39 Mishima N, Kousuke I. Robustness Evaluation of a Miniaturized Machine Tool. 25 th Design Automation Conference[C ]. 1999
40 X. C. Luo, K. Cheng, D. Webb, F. Wardle. Design of Ultra Precision Machine Tools with Applications to Manufacture of Miniature and Micro Components. Journal of Materials Processing Technology. 2005, (167):515~528
41 HR8 Ultrasonic Motor User Manual. Nan motion Data Systems Inc.2005
42雷尼绍RG2直线光栅编码器系统.北京元茂兴. 2005:2~7
43机械装着用モ〡タ&スピンドル. NSK Nakanishi Inc. 2004:2~41
44曹树谦,张文谦等.振动结构模态分析(理论、实验与应用).天津大学出版社, 2002:1~3, 17~27
45 J N Juang, Pappa R. An Eigensystem Realization Algorithm for Modal Parameter Identification and Model Reduction. J. of Guidance, Control and Dynamics, 1985:620~627