摘要
随着制造业的快速发展,需要大量的数控设备,其中,数控落地镗铣床是使用最为广泛的设备之一,本文作者受某企业的委托设计开发了数控落地镗铣床。
首先按照用户对机床的设计要求基于CAD工程软件设计了机床工程图样,并按照工程图样制造了TJK6916数控落地镗铣床样机。
深入分析研究机床部件之间的结合部问题,通过对机床样机各个结合部采用激振器激振、加速度传感器拾振的方式进行模态试验,获得了机床各个结合部的振动信号,并将采集到的振动信号导入用Lab VIEW编写的模态识别程序,获得了各结合部的模态参数,再利用有限元参数优化识别方法识别出各结合部的刚度和阻尼参数；利用COMBIN14单元模拟识别出的结合部刚度和阻尼参数建立TJK6916数控落地镗铣床整机有限元模型,并对整机进行模态分析得到了整机的各阶固有频率和振型；为验证有限元理论分析结果的正确性,对整机进行模态试验分析,将理论分析结果和试验分析结果相比较,证明了有限元模型的正确性,分析了产生误差的原因；根据模态分析的结果,分析了机床结构的薄弱环节,并对滑座、主轴箱、滑枕等主要部件进行了结构优化设计,对X轴传动系统、支撑固定结构、锁紧机构等机床结合部的联结方式及联结装置进行了创新设计,本人和团队成员共取得了5项国家专利。
对优化后的机床结构,再在ansys中定义镗床立柱和主轴箱单元类型、材料、定义网格尺寸、划分网格,然后输出k文件,并在ls-prepost中编辑k文件,定义主轴箱运动关键字及边界条件,编辑以后,递交dyna971求解器求解,并运用1s-prepost对计算后的结果后置处理。利用动态模拟仿真,观察主轴箱在上下移动时对镗床立柱的影响,最后进行立柱应力、应变及能量的后处理,从分析数据看,机床的动态特性良好。
通过市场调查,比较分析了当前国内外同类机床的电气控制系统,数控落地镗铣床的限位装置可靠性要求高,如果一旦失效将发生严重的事故。本文研究了适用于数控镗铣床的限位控制的负逻辑控制原理模型,并基于该模型设计开发了X、Y、Z轴的限位控制电路,并用于机床的控制电路的实际中,取得了良好的效果。
深入研究分析了数控落地镗铣床加工零件的特征,基于GT技术创新地提出了适合于数控落地镗铣床加工零件特征的分组方法,按照该分组方法研究开发了模块化的参数化数控加工程序,并基于VB开发软件将模块化程序进行封装构建了适合于数控镗铣床加工的数控加工程序的自动编程系统。
综合应用上述的研究成果,完整地设计、生产出了数控落地镗铣床,产品已投入市场,使用效果良好。为同类机床的开发研究提供参考,对提高落地式镗铣床产品的市场竞争力具有较大工程意义。此外,本文的研究分析方法对其它类型机床的改进也具有一定的参考价值和借鉴意义。
With the rapid development of manufacturing, a large number of CNC equipment are needed, in which CNC horizontal boring and milling machine tools is one of the most widely devices. In this situation, the author of the thesis has designed and developed CNC horizontal boring and milling machine tools entrusted by the enterprise.
First, according to the users'requirements, the author designed the engineering drawing on the basis of CAD engineering software, and then manufactured the prototype of TJK6916CNC horizontal boring and milling machine tools.
Deeply analyzing and researching the problems of the joints between the parts, by means of vibration exciter exciting and acceleration transducer picking up each joint part of the prototype machine, modal testing is done and the machine tools'vibration signals are obtained. Then collecting vibration sigoals are put into modal identification procedures programming by Lab VIEW, modal parameters of each joint parts are achieved and stiffness and damping parameters of each joint parts are identified by using the optimization recognition method of the finite element parameter. By using COMBIN14unit to simulate the identified joint stiffness and damping parameters of each joint part, the finite element model of the complete machine is established, and the modal analysis is carried out to get the each steps natural frequency and vibration type. In order to verify the finite element theory, the whole machine's modal test is analyzed, the analysis results of the theoretical and the test is compared, the finite element model is proved to be true, and the reasons of error is analyzed. According to the results of modal analysis, the weak unit of the machine tools structure is analyzed, the structures of the major components, such as the sliding seat, the spindle box, ram, are designed optimized. Furthermore, the creation design of coupling form and device of the machine tools'joint parts are carried out, for example, the transmission system along the X axis, supporting and fixing structure and the locking mechanism of machine tools. As a consequence, good dynamic property is obtained with the whole machine so as to the author and the team members have obtained five national patents.
For optimized machine tools'structure, the type of boring machine bed and spindle box unit, material, mesh size were defined, meshing was completed and k file was output in Ansys. The k file was edited; the keyword&boundary conditions of the spindle box movement were defined in1s-prepost. After editing, they were submitted to dyna971solver to solve, the calculated result was treated by using1s-prepost. The influence on boring machine bed was observed by the use of dynamic simulation, when the spindle box moved up and down. Then, the post-processing of the bed stress, strain and energy has good dynamic characteristics.
Having conducted market research and compared the electrical control system of current similar machine at home and abroad, once failure of which happens, serious accident will follow, with high reliability requirements of the limiting device of CNC Horizontal boring and milling machine. This paper studies the negative logic control theory model of limit control suitable for the applicability of CNC Horizontal boring and milling machine, and develops the limit control circuits of X, Y and Z axis based on the model. Later, good results are achieved in application of the circuits in practice.
Thoroughly researching and analyzing of the processing parts'features of CNC horizontal boring and milling machine tools, the paper has put forward an innovative method of grouping suitable for which based on the GT technology innovation. According to the method of grouping, the digital control machining programs of modularization and parameterization have been researched and developed and modularization programs have been packaged to construct automatic programming system suitable for CNC Horizontal boring and milling machine based on VB software.
With the general application of the research conclusion above, the CNC horizontal boring and milling machine has been designed and produced completely and put into market with good results. The machine tools provides reference for development and research of the similar one. And it has great engineering significance to elevate the market competitiveness of these products. In addition, the research and analysis methods in the article also have certain reference significance in the improvement of other types of machine tools.
引文
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