【摘要】：非回轉(zhuǎn)對(duì)稱(chēng)曲面光學(xué)元件以其優(yōu)越的光學(xué)性能已成為光電信息技術(shù)與光通信技術(shù)中的核心元器件,并在空間探索、航空航天、國(guó)防以及民生等眾多領(lǐng)域被廣泛且普遍應(yīng)用。由于非回轉(zhuǎn)對(duì)稱(chēng)曲面光學(xué)元件的表面形貌復(fù)雜、面形精度要求高,傳統(tǒng)的曲面加工技術(shù)以及LIGA技術(shù)、蝕刻技術(shù)等新近發(fā)展的曲面加工技術(shù)都不能實(shí)現(xiàn)非回轉(zhuǎn)對(duì)稱(chēng)曲面光學(xué)元件高效率、高精度、大批量加工。隨著超精密金剛石車(chē)床與快速刀具伺服系統(tǒng)的研究發(fā)展,基于快速刀具伺服(Fast Tool Servo,FTS)系統(tǒng)的金剛石刀具車(chē)削加工技術(shù)已經(jīng)成為了一種高效率、高精度、高柔性的非回轉(zhuǎn)對(duì)稱(chēng)曲面光學(xué)元件加工技術(shù)。其中,漸進(jìn)式鏡片曲面是一種典型的非回轉(zhuǎn)對(duì)稱(chēng)曲面,它是一種擁有多個(gè)焦距的鏡片曲面,區(qū)別于傳統(tǒng)的老花鏡曲面,漸進(jìn)式鏡片曲面沒(méi)有使用雙焦距老花鏡時(shí)眼球必須不斷切換適應(yīng)不同焦距的疲勞感,已經(jīng)成為老視人群的最佳選擇。但目前漸進(jìn)式鏡片的驗(yàn)配時(shí)間長(zhǎng)、價(jià)格昂貴,實(shí)現(xiàn)其高效率、高精度、低價(jià)格加工的實(shí)現(xiàn)是一個(gè)亟待解決的問(wèn)題。為實(shí)現(xiàn)漸進(jìn)式鏡片曲面元件的加工,本文根據(jù)給定性能要求設(shè)計(jì)一款FTS裝置。通過(guò)對(duì)FTS裝置設(shè)計(jì)過(guò)程的運(yùn)動(dòng)參數(shù)尤其是其加速度的進(jìn)行分析,且根據(jù)漸進(jìn)式鏡片曲面面形完成FTS裝置的帶寬設(shè)計(jì),并根據(jù)漸進(jìn)式鏡片曲面切削深度確實(shí)FTS裝置行程。為保證漸進(jìn)式鏡片曲面的加工精度,設(shè)計(jì)的FTS裝置影具有大的帶寬,也就是較高的頻率響應(yīng),由于鏡片曲面不同位置的高度差較大,達(dá)到毫米級(jí),設(shè)計(jì)的FYS裝置應(yīng)具備較大的工作行程。并對(duì)加工過(guò)程中切削力與切削角度變化進(jìn)行分析,根據(jù)分析結(jié)果完成FTS裝置的布局形式以及導(dǎo)向機(jī)構(gòu)、驅(qū)動(dòng)裝置、傳感器的選擇。根據(jù)FTS裝置的結(jié)構(gòu)布局和元件選擇完成其主要構(gòu)成部分:空氣靜壓導(dǎo)軌、金剛石刀具刀架等結(jié)構(gòu)設(shè)計(jì)與有限元分析以及氣浮裝置的設(shè)計(jì)與參數(shù)計(jì)算。并根據(jù)上述分析完成FTS裝置的整體結(jié)構(gòu)設(shè)計(jì)。根據(jù)漸進(jìn)式鏡片曲面的面形方程完成金剛石刀具幾何參數(shù)的選擇,利用MATLAB完成鏡片曲面切削加工軌跡規(guī)劃并離散出刀具刀尖點(diǎn)位置的數(shù)據(jù)點(diǎn),確定機(jī)床主軸、X向工作臺(tái)與FTS裝置的運(yùn)動(dòng)軌跡曲線。采用等距點(diǎn)法計(jì)算刀尖離散數(shù)據(jù)點(diǎn)在二維徑向截面輪廓曲線上的等距點(diǎn),并采用埃爾米特插值完成離散數(shù)據(jù)點(diǎn)的刀尖圓弧半徑補(bǔ)償。本文分析了FTS裝置通過(guò)試切法減少對(duì)刀誤差和刀具中心高誤差對(duì)漸進(jìn)式鏡片曲面加工面形精度的影響。為減少FTS裝置對(duì)刀的刀具中心高誤差,基于螺旋微分頭設(shè)計(jì)一臺(tái)高剛度、高分辨率的精密升降臺(tái)�；谝陨涎芯�,采用FTS裝置在自主研究的精密金剛石車(chē)床上完成漸進(jìn)式鏡片曲面的加工,并對(duì)加工結(jié)果進(jìn)行檢測(cè)分析,驗(yàn)證FTS裝置結(jié)構(gòu)設(shè)計(jì)和刀具刀尖點(diǎn)運(yùn)動(dòng)軌跡規(guī)劃的正確性。
[Abstract]:Non-rotational curved surface optical elements have become the core components of optoelectronic information technology and optical communication technology due to their superior optical properties and have been widely used in many fields such as space exploration aerospace national defense and people's livelihood. Due to the complexity of surface morphology and the high precision of surface shape of non-rotational symmetric curved surface optical elements, traditional curved surface processing technology and LIGA technology, Recently developed surface machining techniques such as etching technology can not realize high efficiency, high precision and mass machining of non-rotational symmetric curved surface optical elements. With the development of ultra-precision diamond lathe and rapid cutting tool servo system, the diamond tool turning technology based on fast tool servo (Fast Tool Servo,FTS system has become a kind of high efficiency and high precision. High flexible machining technology for non-rotational symmetric curved surface optical elements. Among them, the progressive lens surface is a typical non-rotational symmetric surface, it is a lens surface with multiple focal lengths, which is different from the traditional presbyopic glasses surface. Progressive lens surface without double focus presbyopic glasses has become the best choice for the elderly people because their eyeballs must constantly change and adapt to the fatigue of different focal lengths when they do not use double focus presbyopic glasses. However, it is an urgent problem to realize the high efficiency, high precision and low price processing of the progressive lens because of its long matching time and high price. In order to realize the machining of the progressive lens surface element, a FTS device is designed according to the given performance requirements. Based on the analysis of the motion parameters, especially the acceleration of the FTS device, the bandwidth of the FTS device is designed according to the surface shape of the progressive lens, and the stroke of the FTS device is confirmed according to the cutting depth of the progressive lens surface. In order to ensure the machining accuracy of the progressive lens surface, the FTS device designed has a large bandwidth, that is, a higher frequency response. Because of the large height difference in different positions of the lens surface, it reaches the millimeter level. The designed FYS device should have a larger working stroke. The changes of cutting force and cutting angle during machining are analyzed. According to the analysis results, the layout of FTS device and the selection of guiding mechanism, driving device and sensor are completed. According to the structure layout and component selection of FTS device, the main components are designed and analyzed by finite element method, such as air static guide rail, diamond tool holder, and air floatation device design and parameter calculation. According to the above analysis, the overall structure design of FTS device is completed. According to the surface equation of progressive lens surface, the geometric parameters of diamond tool are selected, and the cutting path planning of lens surface is completed by MATLAB, and the data points of cutter tip position are discretized. Determine the track curve of machine tool spindle, X-direction table and FTS device. The isometric point method is used to calculate the equidistant points of the discrete data points on the 2-D radial section contour curve, and the Hermite interpolation is used to compensate the radius of the cutter tip of the discrete data points. In this paper, the influence of tool error and tool center height error on the machining accuracy of progressive lens surface in FTS device is analyzed by means of trial cutting method. In order to reduce the error of tool center height in FTS device, a precise lifting platform with high stiffness and high resolution was designed based on helical differential head. Based on the above research, the FTS device is used to finish the machining of the progressive lens surface on the precision diamond lathe, and the processing results are tested and analyzed. Verify the correctness of FTS device structure design and tool tip motion trajectory planning.
【學(xué)位授予單位】：哈爾濱工業(yè)大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類(lèi)號(hào)】：TG51

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本文編號(hào)：2268013