铣削表面形貌的多尺度表征与仿真技术

发布时间：2018-06-06 15:32

本文选题：表面形貌 + 球头铣刀　；参考：《浙江大学》2015年博士论文

【摘要】：本文结合国家重点基础研究发展计划项目“复杂空气分离类成套装备超大型化与低能耗化的关键科学问题”课题“关键部件高强度大构件保质制造技术”(编号：2011CB706505)和国家自然科学基金项目“基于功能-结构并行分解的公差设计理论与方法”(51275464),开展了零件表面的多尺度建模、铣削过程的几何与物理建模、铣削表面形貌的多尺度仿真、基于离散模态系数的铣削表面形貌表征等方面的研究。第1章：综述了零件表面形貌多尺度表征、加工过程建模、铣削表面形貌仿真的研究现状,分析了课题的研究背景和意义,给出了本课题的研究内容和总体框架。第2章：构建了零件表面多尺度误差的表征数学模型；提出了基于改进离散模态分解法(IDMD)的误差表面多尺度建模方法,即通过理想表面的多尺度网格划分、单位化幅值场向量的生成、几何误差系数的生成、尺寸误差系数的生成、不同尺度误差的融合,实现零件误差表面的多尺度建模,同时达到计算时间与精度的平衡。第3章：不同公差原则下,零件表面形貌的多尺度表征模型中各误差系数将大为不同。针对上述问题,本章提出了各公差原则下零件表面模型几何误差与尺寸误差系数的生成方法,实现了零件公差信息与几何模型的统一。第4章：通过研究考虑定位面几何误差影响条件下的定位误差计算方法,分析机床几何误差、主轴误差、工艺参数引起的误差等多源误差对零件精度的耦合机理,提出了多源误差耦合作用下的刀具-零件接触准则,构建了加工过程的几何及物理模型；基于球头铣刀的准静态及动力学结构模型,利用刀具的准静态变形与动态位移响应修正零件加工过程几何模型,实现对铣削表面形貌的多尺度仿真；最后,通过实验验证了本章所提出的方法。第5章：通过仿真分析不同切削条件下的铣削表面形貌,揭示了不同切削参数对铣削表面粗糙度Ra的影响规律；提出了一种基于离散模态系数的铣削表面形貌的表征方法,该方法能够反映刀具残留轮廓的不规则程度,同时能够更加直观表征切削参数与零件表面形貌的关系。第6章：基于MATLAB开发了球头刀5轴铣削表面形貌多尺度预测与分析系统;以MIKRON UCP 600五轴铣床为例对本文所涉及的机床几何误差、切削力系数、刀具的振动模态参数进行了实验测量。第7章：总结了本文的主要研究内容和创新点,对今后的研究工作进行了展望。
[Abstract]:This paper, based on the national key basic research and development plan project, "key scientific problems of supersize and low energy consumption of complex air separation equipment," "key components of high strength and large component conservation manufacturing technology" (number: 2011CB706505) and National Natural Science Foundation Project "based on functional structure parallel decomposition of the public The theory and method of differential design (51275464), the multi-scale modeling of parts surface, geometric and physical modeling of milling process, multi-scale simulation of milling surface morphology, and surface morphology characterization of milling surface based on discrete modal coefficients are studied. The first chapter is a review of multi scale characterization of surface morphology, modeling and milling of machining process. The research background and significance of the surface topography simulation are analyzed. The research content and general framework of this topic are given. Second chapter: the mathematical model of multi-scale error characterization of the parts surface is constructed; a multi-scale modeling method based on the improved discrete modal decomposition method (IDMD) is proposed, that is, through the ideal table. The multiscale mesh division of the surface, the generation of the unit amplitude field vector, the generation of the geometric error coefficient, the generation of the dimension error coefficient and the fusion of the different scale errors, the multi-scale modeling of the parts error surface is realized, and the balance of the calculation time and the precision is achieved. The third chapter: the multi scale table of the surface morphology of the parts under the principle of different tolerance. Each error coefficient in the model will be greatly different. In this chapter, the method of generating the geometric error and the dimension error coefficient of the surface model of parts under the principle of tolerance is put forward, and the integration of the tolerance information and the geometric model of the parts is realized. The fourth chapter: the calculation of the location error in the condition of the geometric error of the positioning surface is calculated. Method, the coupling mechanism of multi source error, such as geometric error of machine tool, spindle error, error caused by process parameters, and the coupling principle of tool parts under the coupling of multi source error is proposed, and the geometric and physical model of machining process is constructed, and the quasi static and dynamic structural model based on the ball end milling cutter is used to make use of the tool. The geometric model of the part machining process is corrected by the quasi static deformation and dynamic displacement response. The multi-scale simulation of the surface morphology of the milling surface is realized. Finally, the method proposed in this chapter is verified by the experiment. Fifth chapter: through the simulation analysis of the milling surface morphology under different cutting conditions, the surface roughness of different cutting parameters is revealed to the milling surface roughness. The influence law of Ra is presented. A method of characterization of milling surface topography based on discrete modal coefficients is proposed. This method can reflect the irregular degree of the tool residual contour, and can more intuitively characterize the relationship between the cutting parameters and the surface morphology of the parts. In the sixth chapter, the multi-scale surface topography of the 5 axis milling of the ball head cutter is developed. The MIKRON UCP 600 five axis milling machine is taken as an example to measure the geometric error of the machine tool, the cutting force coefficient and the vibration modal parameters of the tool. The seventh chapter is a summary of the main research contents and innovation points in this paper, and the future research work is prospected.
【学位授予单位】：浙江大学
【学位级别】：博士
【学位授予年份】：2015
【分类号】：TG54

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