基于过程监测的滚珠丝杠硬旋铣关键技术研究

发布时间：2018-01-30 03:18

本文关键词： 硬旋铣滚珠丝杠成形精度行程偏差 OPC 测力仪过程监测刀具破损 PCBN　出处：《南京理工大学》2016年博士论文　论文类型：学位论文

【摘要】：本文研究了滚珠丝杠螺纹硬旋铣工艺的成形过程和加工过程监测技术及其在工艺优化与预报中的应用,解决了硬旋铣加工淬硬GCr15滚珠丝杠螺纹的刀具几何设计、装刀设计、刀具材料优选、刀具破损预报、加工精度预报等关键技术,为实现硬旋铣工艺的高效高精加工,以及在线监控和智能制造提供了有力的技术支撑。首先,分析了硬旋铣加工中旋铣圆直径、螺纹牙型参数、刀盘安装角对滚珠丝杠螺纹滚道成形精度的影响,提出了基于共轭曲面接触线理论的控制滚珠丝杠滚道廓形精度的刀具设计及装刀设计方法。通过硬旋铣切削层参数的几何解析,分析并验证了硬旋铣螺纹滚道两侧面的表面完整性,以及刀具切削刃不同位置的工作状态,明确了刀具切入破损的发生位置,为硬旋铣刀具性能的改进奠定了基础。其次,使用电压型三向压电式力传感器研制了一套硬旋铣刀齿切削力测试系统,建立并验证了基于剪切效应和犁切效应的硬旋铣刀齿切削力预报模型,通过硬旋铣刀齿切削力的分析,明确了硬旋铣刀具切出破损的发生位置。利用开放式数控系统的OPC通信技术开发了一款用于硬旋铣过程监测的机床状态信息访问软件,为工艺过程监测与预报提供了重要的技术手段。再次,通过硬旋铣加工过程中伺服电机输出位移的监测,讨论了机床运动误差的评价方法和数据处理方法,揭示了工件转速对硬旋铣机床匀速段速度波动误差的线性影响规律。通过跟刀架驱动电机输出力矩的监测,给出了工件夹紧系数的合理取值。通过硬旋铣刀齿切削力的监测,检验了硬旋铣工具系统的刚度,明确了硬旋铣工艺的切削振动类型。通过切削力回归方程的建立,给出了利用切削用量控制硬旋铣切削振动的措施。然后,通过不同刀具材料和刀具刃口的PCBN刀具硬旋铣对比切削试验,研究了硬旋铣刀具的失效形式和抗磨损特性,明确了硬旋铣刀具的主要刃口磨损位置,给出了适合硬旋铣加工的PCBN刀具材料和刀具刃口设计,并给出了加工不同精度等级滚珠丝杠的刀具切削用量推荐值。利用数控系统中伺服电机电流环的监测信号,提出了一种预报硬旋铣刀具破损的方法。最后,分析并明确了影响硬旋铣滚珠丝杠行程变动量的主要误差源和主要影响因素。通过支撑架支撑力的监测,提出了一种预报硬旋铣滚珠丝杠行程偏差的方法。运用线弹性力学理论,研究了工件转速、切削力、跟刀架跨距、夹持长度和约束类型对硬旋铣滚珠丝杠行程变动量的影响,并在此基础上探讨了控制硬旋铣滚珠丝杠行程偏差的技术途径。
[Abstract]:In this paper, the forming process and monitoring technology of ball screw thread hard rotary milling process and its application in process optimization and prediction are studied. The key techniques such as tool geometry design, tool loading design, tool material selection, tool breakage prediction and machining precision prediction for hardened GCr15 ball screw thread are solved. In order to realize the high efficiency and high precision machining of hard rotary milling process and on-line monitoring and intelligent manufacturing, this paper provides a powerful technical support. Firstly, the circle diameter and thread profile parameters in hard rotary milling process are analyzed. The influence of the installation angle of the cutter on the forming accuracy of the ball screw thread raceway. Based on the contact line theory of conjugate surface, the tool design and tool mounting design method for controlling the profile accuracy of ball screw raceway are presented, and the geometric analysis of the parameters of the cutting layer by hard rotary milling is presented. The surface integrity of the two sides of the raceway and the working state of the cutting edge at different positions are analyzed and verified. It lays a foundation for the improvement of the performance of the hard rotary milling cutter. Secondly, a set of measuring system for the cutting force of the hard rotary milling cutter teeth is developed by using the voltage-type three-way piezoelectric force sensor. Based on shear effect and ploughing effect, the prediction model of cutting force of hard rotary milling cutter teeth is established and verified, and the analysis of cutting force of hard rotary milling cutter teeth is carried out. In this paper, the position of the cutting damage of the hard rotary milling tool is defined. Using the OPC communication technology of the open CNC system, a machine tool state information access software is developed for the monitoring of the hard rotary milling process. It provides an important technical means for process monitoring and prediction. Thirdly, through the monitoring of the output displacement of servo motor in the process of hard rotary milling, the evaluation method and data processing method of machine tool motion error are discussed. The linear influence of workpiece rotational speed on the velocity fluctuation error in uniform section of hard rotary milling machine is revealed, and the output torque of motor driven by the tool holder is monitored. The reasonable value of the clamping coefficient of the workpiece is given, and the rigidity of the hard rotary milling tool system is tested by monitoring the cutting force of the hard rotary milling cutter teeth. The cutting vibration type of hard rotary milling technology is defined. Through the establishment of the regression equation of cutting force, the measures of controlling the cutting vibration of hard rotary milling by cutting parameters are given. Through the contrast cutting test of PCBN tools with different cutting materials and cutting edges, the failure forms and wear resistance characteristics of hard rotary milling tools are studied, and the main cutting edge wear positions of hard rotary milling tools are determined. The PCBN cutting tool material and cutting edge design suitable for hard rotary milling are given. The cutting parameters of the ball screw with different precision are recommended. By using the monitoring signal of the servo motor current ring in the numerical control system, a method to predict the damage of the hard rotary milling tool is proposed. The main error sources and main influencing factors affecting the stroke change of the hard rotary ball screw are analyzed and defined. The supporting force of the support frame is monitored. In this paper, a method of predicting the travel deviation of hard rotary ball screw is presented. The rotation speed of workpiece, cutting force and the span of tool holder are studied by using the theory of linear elasticity. The influence of clamping length and constraint type on the stroke variation of hard rotary milling ball screw is discussed. On the basis of this, the technical ways to control the stroke deviation of hard rotary milling ball screw are discussed.
【学位授予单位】：南京理工大学
【学位级别】：博士
【学位授予年份】：2016
【分类号】：TG659;TG54

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