影响工作精度的五轴数控机床联动性能测试方法研究
发布时间：2018-08-14 15:51
【摘要】：制造业是国家国民经济的支柱产业,数控机床特别是五轴数控机床,已成为各行业不可或缺的工作母机,是一个国家生产能力和自动化水平的重要标志。在高速高精密加工过程中,五轴机床的联动性能已成为影响工件加工质量的重要因素,研究影响工作精度的五轴机床联动性能测试问题对提高五轴联动机床的加工能力和加工精度有着十分重要的意义。本文围绕影响五轴数控机床工作精度的多轴联动性能问题,研究加工过程中的多轴联动误差形成机理,对数控机床伺服控制系统性能在多轴联动精度、标准试件表面质量上的影响规律进行研究,探寻针对五轴数控机床联动精度的高效检测手段,研究基于RTCP(Rotation tool center point)和S试件的五轴机床联动性能检测方法,揭示五轴机床多轴联动时刀具刀尖点误差以及S试件的异常表面纹理形成机理。研究五轴数控机床联动误差溯源方法,为五轴数控机床的动态参数调整提供指导性建议。研究内容与各章节对应关系为:第二章中依据五轴机床结构建立五轴机床联动误差模型。第三章研究在标准检验试件上局部异常表面形成中五轴机床联动性能的作用机理。第四章开展基于RTCP检测的五轴机床联动性能测试原理分析。第五章开展基于RTCP检测的五轴机床联动性能测试轨迹比较研究。第六章开展基于RTCP特定检测轨迹下的五轴机床联动性能差异溯源方法研究。经本文工作得到以下研究成果:(1)揭示五轴机床联动加工中机床联动性能与工件表面结构之间的内在联系规律。利用五轴机床联动误差模型,仿真分析五轴机床联动性能对工件轮廓误差的作用过程,通过高通滤波提取轮廓误差中表面微观成分,放大后直接叠加在工件表面,显示出不同位置的表面质量,证明五轴机床联动误差是引起工件表面异常的主要原因。以标准试件NAS979圆锥台试件和S试件为研究对象,分析其几何特征和机床加工运动特征,发现S试件具备变化的曲率、曲面不连续、丰富的运动状态等特征。通过标准试件仿真和试切实验,证明表面质量与机床联动误差之间的内在联系。通过对比分析相同联动性能状态下的NAS979圆锥台试件和S试件的表面质量,发现S试件不同位置的表面质量存在明显差异,相比NAS979圆锥台试件,S试件可更直观有效地展示五轴机床联动性能的优劣。基于S试件表面质量的五轴机床联动性能测试方法可用于直观有效地检测五轴机床加工过程中的联动性能,保障五轴机床的加工能力和加工精度。(2)提出一种不同于ISO标准的RTCP检测轨迹来有效便捷地展现五轴机床联动性能。平动轴和旋转轴动态误差对刀具刀尖点误差有着不同的作用规律,表明基于RTCP的五轴机床联动性能测试方法可以有效地检测五轴机床的联动性能。通过分析平动轴运动和旋转轴运动之间的关系,确定利用旋转轴运动参数表征RTCP检测轨迹的定义方法。分析旋转轴运动参数对RTCP检测结果的影响规律,提出不同于ISO标准轨迹的基于余弦函数的检测轨迹定义方法,并定义了4条余弦轨迹。对比分析4条余弦轨迹和ISO标准轨迹的几何特性、运动特性和运行检测轨迹时刀具刀尖点误差对机床联动性能参数的灵敏度,发现圆形轨迹s2T和8字形轨迹s3T具有变化的曲率、更丰富的联合运动速度状态和更高的误差灵敏度。以灵敏度最优为目标函数,基于遗传算法优化RTCP检测轨迹,获得机床各类动态性能相应的优化检测轨迹——s3T轨迹、345sT轨迹和390sT轨迹。通过仿真与实验,表明不同的机床联动误差类型在不同的RTCP检测轨迹下有不尽相同的误差表现,验证RTCP优化检测轨迹在五轴机床联动性能检测能力上的优越性。(3)提出一种基于图像识别的联动误差类别溯源方法和基于轨迹相似度的联动误差精确溯源方法相结合的五轴机床联动性能差异溯源方法。以执行8字形检测轨迹时刀具刀尖点误差为研究对象,依据不同五轴机床联动性能下刀具刀尖点误差轨迹的差异特征,将机床联动误差分为75类,对刀具刀尖点误差轨迹在多维度中的轨迹图形进行归一化,并利用傅里叶描述子提取刀具刀尖点误差轨迹特征,与机床联动误差标准图库中的误差轨迹图比对,找寻最相近的图形,确定五轴机床联动误差类型。通过轨迹相似度溯源方法准确溯源得到五轴机床各驱动轴联动性能差异。通过五轴机床联动性能差异溯源实验,验证基于图像识别和轨迹相似度的五轴机床联动联系性能差异溯源方法可以准确的溯源五轴机床联动性能差异,为五轴机床伺服参数的调整提供指导性建议。利用图像识别方法缩小误差范围,再利用轨迹相似度准确溯源的溯源方法既保证了溯源结果的准确性,又提升了溯源效率,从而可以更有效、便捷地利用刀具刀尖点误差溯源五轴机床联动性能差异。
[Abstract]:Manufacturing industry is the pillar industry of the national economy. NC machine tools, especially five-axis NC machine tools, have become indispensable to all walks of life and an important symbol of national production capacity and automation level. It is very important to study the testing problem of the five-axis machine tool linkage performance which affects the working accuracy for improving the machining ability and precision of the five-axis machine tool. The effect of servo control system on multi-axis linkage accuracy and surface quality of standard specimens is studied. An efficient testing method for five-axis NC machine tool linkage accuracy is explored. The testing method of five-axis machine tool linkage performance based on RTCP (Rotation Tool Center Point) and S specimens is studied to reveal the cutting tool of five-axis machine tool in multi-axis linkage. This paper studies the Traceability Method of 5-axis NC machine tool linkage error, and provides guidance suggestions for dynamic parameter adjustment of 5-axis NC machine tool. The mechanism of five-axis machine tool linkage performance in the formation of local abnormal surfaces on standard test specimens is studied. Chapter 4 analyzes the testing principle of five-axis machine tool linkage performance based on RTCP testing. Chapter 5 compares the testing trajectories of five-axis machine tool linkage performance based on RTCP testing. The following research results have been obtained: (1) To reveal the inherent relationship between the linkage performance and the surface structure of the workpiece in the five-axis machine tool linkage machining. In the process of action, the surface micro-component of contour error is extracted by high-pass filter, and then magnified and directly superimposed on the surface of the workpiece to show the surface quality of different positions. It is proved that the five-axis machine tool linkage error is the main cause of abnormal surface of the workpiece. It is found that S specimens possess the characteristics of varying curvature, discontinuous curved surface and abundant motion state. The internal relationship between surface quality and linkage error of machine tools is proved by simulation and test of standard specimens. Compared with the NAS979 conical table, the S specimen can show the advantages and disadvantages of the five-axis machine tool linkage performance more intuitively and effectively. (2) This paper presents a RTCP testing track which is different from ISO standard to display the linkage performance of five-axis machine tools effectively and conveniently. The dynamic errors of translational axis and rotational axis have different effects on tool tip errors, indicating that the RTCP-based testing method for five-axis machine tools is feasible. By analyzing the relationship between translational axis motion and rotational axis motion, the definition method of RTCP detection trajectory characterized by rotational axis motion parameters is determined. The influence of rotational axis motion parameters on RTCP detection results is analyzed, and the detection method based on cosine function different from ISO standard trajectory is proposed. Four cosine trajectories are defined. The geometric characteristics of four cosine trajectories and ISO standard trajectories, the sensitivity of tool tip error to machine tool linkage performance parameters are compared and analyzed. It is found that circular trajectory s2T and zigzag trajectory s3T have variable curvature and more abundant joint velocity. Degree state and higher error sensitivity. Taking the optimum sensitivity as the objective function, the RTCP detection trajectory is optimized based on genetic algorithm. The corresponding optimized detection trajectories of various dynamic performances of machine tools are obtained: s3T trajectory, 345sT trajectory and 390sT trajectory. The results show that the RTCP optimized detection trajectory is superior to the five-axis machine tool in the detection ability of linkage performance. (3) An image recognition-based linkage error category tracing method and a trajectory similarity-based linkage error precise tracing method are proposed. Based on the different characteristics of tool tip error trajectory under different five-axis machine tool linkage performance, the machine tool linkage error is divided into 75 categories. The tool tip error trajectory is normalized in multi-dimension, and the tool is extracted by Fourier descriptor. The characteristics of tool point error trajectory are compared with the error trajectory in the standard library of machine tool linkage error to find the closest graph and determine the type of five-axis machine tool linkage error. This paper proves that the Traceability Method Based on image recognition and trajectory similarity can accurately trace the difference of five-axis machine tool linkage performance and provide guidance suggestions for adjusting servo parameters of five-axis machine tool. The accuracy of the traceability results is guaranteed, and the traceability efficiency is improved. Therefore, the tool tip error can be used to trace the linkage performance difference of five-axis machine tools more effectively and conveniently.
【学位授予单位】：电子科技大学
【学位级别】：博士
【学位授予年份】：2017
【分类号】：TG659
本文编号：2183364
[Abstract]:Manufacturing industry is the pillar industry of the national economy. NC machine tools, especially five-axis NC machine tools, have become indispensable to all walks of life and an important symbol of national production capacity and automation level. It is very important to study the testing problem of the five-axis machine tool linkage performance which affects the working accuracy for improving the machining ability and precision of the five-axis machine tool. The effect of servo control system on multi-axis linkage accuracy and surface quality of standard specimens is studied. An efficient testing method for five-axis NC machine tool linkage accuracy is explored. The testing method of five-axis machine tool linkage performance based on RTCP (Rotation Tool Center Point) and S specimens is studied to reveal the cutting tool of five-axis machine tool in multi-axis linkage. This paper studies the Traceability Method of 5-axis NC machine tool linkage error, and provides guidance suggestions for dynamic parameter adjustment of 5-axis NC machine tool. The mechanism of five-axis machine tool linkage performance in the formation of local abnormal surfaces on standard test specimens is studied. Chapter 4 analyzes the testing principle of five-axis machine tool linkage performance based on RTCP testing. Chapter 5 compares the testing trajectories of five-axis machine tool linkage performance based on RTCP testing. The following research results have been obtained: (1) To reveal the inherent relationship between the linkage performance and the surface structure of the workpiece in the five-axis machine tool linkage machining. In the process of action, the surface micro-component of contour error is extracted by high-pass filter, and then magnified and directly superimposed on the surface of the workpiece to show the surface quality of different positions. It is proved that the five-axis machine tool linkage error is the main cause of abnormal surface of the workpiece. It is found that S specimens possess the characteristics of varying curvature, discontinuous curved surface and abundant motion state. The internal relationship between surface quality and linkage error of machine tools is proved by simulation and test of standard specimens. Compared with the NAS979 conical table, the S specimen can show the advantages and disadvantages of the five-axis machine tool linkage performance more intuitively and effectively. (2) This paper presents a RTCP testing track which is different from ISO standard to display the linkage performance of five-axis machine tools effectively and conveniently. The dynamic errors of translational axis and rotational axis have different effects on tool tip errors, indicating that the RTCP-based testing method for five-axis machine tools is feasible. By analyzing the relationship between translational axis motion and rotational axis motion, the definition method of RTCP detection trajectory characterized by rotational axis motion parameters is determined. The influence of rotational axis motion parameters on RTCP detection results is analyzed, and the detection method based on cosine function different from ISO standard trajectory is proposed. Four cosine trajectories are defined. The geometric characteristics of four cosine trajectories and ISO standard trajectories, the sensitivity of tool tip error to machine tool linkage performance parameters are compared and analyzed. It is found that circular trajectory s2T and zigzag trajectory s3T have variable curvature and more abundant joint velocity. Degree state and higher error sensitivity. Taking the optimum sensitivity as the objective function, the RTCP detection trajectory is optimized based on genetic algorithm. The corresponding optimized detection trajectories of various dynamic performances of machine tools are obtained: s3T trajectory, 345sT trajectory and 390sT trajectory. The results show that the RTCP optimized detection trajectory is superior to the five-axis machine tool in the detection ability of linkage performance. (3) An image recognition-based linkage error category tracing method and a trajectory similarity-based linkage error precise tracing method are proposed. Based on the different characteristics of tool tip error trajectory under different five-axis machine tool linkage performance, the machine tool linkage error is divided into 75 categories. The tool tip error trajectory is normalized in multi-dimension, and the tool is extracted by Fourier descriptor. The characteristics of tool point error trajectory are compared with the error trajectory in the standard library of machine tool linkage error to find the closest graph and determine the type of five-axis machine tool linkage error. This paper proves that the Traceability Method Based on image recognition and trajectory similarity can accurately trace the difference of five-axis machine tool linkage performance and provide guidance suggestions for adjusting servo parameters of five-axis machine tool. The accuracy of the traceability results is guaranteed, and the traceability efficiency is improved. Therefore, the tool tip error can be used to trace the linkage performance difference of five-axis machine tools more effectively and conveniently.
【学位授予单位】：电子科技大学
【学位级别】：博士
【学位授予年份】：2017
【分类号】：TG659
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