本文關(guān)鍵詞： 硬旋銑 滾珠絲杠 成形精度 行程偏差 OPC 測(cè)力儀 過(guò)程監(jiān)測(cè) 刀具破損 PCBN　出處：《南京理工大學(xué)》2016年博士論文　論文類型：學(xué)位論文

【摘要】：本文研究了滾珠絲杠螺紋硬旋銑工藝的成形過(guò)程和加工過(guò)程監(jiān)測(cè)技術(shù)及其在工藝優(yōu)化與預(yù)報(bào)中的應(yīng)用,解決了硬旋銑加工淬硬GCr15滾珠絲杠螺紋的刀具幾何設(shè)計(jì)、裝刀設(shè)計(jì)、刀具材料優(yōu)選、刀具破損預(yù)報(bào)、加工精度預(yù)報(bào)等關(guān)鍵技術(shù),為實(shí)現(xiàn)硬旋銑工藝的高效高精加工,以及在線監(jiān)控和智能制造提供了有力的技術(shù)支撐。首先,分析了硬旋銑加工中旋銑圓直徑、螺紋牙型參數(shù)、刀盤(pán)安裝角對(duì)滾珠絲杠螺紋滾道成形精度的影響,提出了基于共軛曲面接觸線理論的控制滾珠絲杠滾道廓形精度的刀具設(shè)計(jì)及裝刀設(shè)計(jì)方法。通過(guò)硬旋銑切削層參數(shù)的幾何解析,分析并驗(yàn)證了硬旋銑螺紋滾道兩側(cè)面的表面完整性,以及刀具切削刃不同位置的工作狀態(tài),明確了刀具切入破損的發(fā)生位置,為硬旋銑刀具性能的改進(jìn)奠定了基礎(chǔ)。其次,使用電壓型三向壓電式力傳感器研制了一套硬旋銑刀齒切削力測(cè)試系統(tǒng),建立并驗(yàn)證了基于剪切效應(yīng)和犁切效應(yīng)的硬旋銑刀齒切削力預(yù)報(bào)模型,通過(guò)硬旋銑刀齒切削力的分析,明確了硬旋銑刀具切出破損的發(fā)生位置。利用開(kāi)放式數(shù)控系統(tǒng)的OPC通信技術(shù)開(kāi)發(fā)了一款用于硬旋銑過(guò)程監(jiān)測(cè)的機(jī)床狀態(tài)信息訪問(wèn)軟件,為工藝過(guò)程監(jiān)測(cè)與預(yù)報(bào)提供了重要的技術(shù)手段。再次,通過(guò)硬旋銑加工過(guò)程中伺服電機(jī)輸出位移的監(jiān)測(cè),討論了機(jī)床運(yùn)動(dòng)誤差的評(píng)價(jià)方法和數(shù)據(jù)處理方法,揭示了工件轉(zhuǎn)速對(duì)硬旋銑機(jī)床勻速段速度波動(dòng)誤差的線性影響規(guī)律。通過(guò)跟刀架驅(qū)動(dòng)電機(jī)輸出力矩的監(jiān)測(cè),給出了工件夾緊系數(shù)的合理取值。通過(guò)硬旋銑刀齒切削力的監(jiān)測(cè),檢驗(yàn)了硬旋銑工具系統(tǒng)的剛度,明確了硬旋銑工藝的切削振動(dòng)類型。通過(guò)切削力回歸方程的建立,給出了利用切削用量控制硬旋銑切削振動(dòng)的措施。然后,通過(guò)不同刀具材料和刀具刃口的PCBN刀具硬旋銑對(duì)比切削試驗(yàn),研究了硬旋銑刀具的失效形式和抗磨損特性,明確了硬旋銑刀具的主要刃口磨損位置,給出了適合硬旋銑加工的PCBN刀具材料和刀具刃口設(shè)計(jì),并給出了加工不同精度等級(jí)滾珠絲杠的刀具切削用量推薦值。利用數(shù)控系統(tǒng)中伺服電機(jī)電流環(huán)的監(jiān)測(cè)信號(hào),提出了一種預(yù)報(bào)硬旋銑刀具破損的方法。最后,分析并明確了影響硬旋銑滾珠絲杠行程變動(dòng)量的主要誤差源和主要影響因素。通過(guò)支撐架支撐力的監(jiān)測(cè),提出了一種預(yù)報(bào)硬旋銑滾珠絲杠行程偏差的方法。運(yùn)用線彈性力學(xué)理論,研究了工件轉(zhuǎn)速、切削力、跟刀架跨距、夾持長(zhǎng)度和約束類型對(duì)硬旋銑滾珠絲杠行程變動(dòng)量的影響,并在此基礎(chǔ)上探討了控制硬旋銑滾珠絲杠行程偏差的技術(shù)途徑。
[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.
【學(xué)位授予單位】：南京理工大學(xué)
【學(xué)位級(jí)別】：博士
【學(xué)位授予年份】：2016
【分類號(hào)】：TG659;TG54

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