【摘要】：高速加工技術(shù)在航空航天、汽車、模具等制造業(yè)中應(yīng)用廣泛,是提高加工質(zhì)量和效率的重要手段,國際生產(chǎn)工程學(xué)會(huì)(CIRP)將高速加工技術(shù)確定為21世紀(jì)制造技術(shù)的中心方向之一。微小線段是葉輪、葉片、模具等復(fù)雜曲面零件加工路徑的最廣泛表達(dá)形式,微小線段路徑高速加工已成為復(fù)雜曲面零件高速加工核心技術(shù)之一。微小線段路徑中轉(zhuǎn)角一階不連續(xù)特性會(huì)導(dǎo)致頻繁加減速,成為數(shù)控機(jī)床高速平穩(wěn)運(yùn)動(dòng)的瓶頸。連續(xù)微小線段轉(zhuǎn)角速度平滑和跨段速度規(guī)劃是連續(xù)微小線段插補(bǔ)的最大難題,至今仍是先進(jìn)數(shù)控系統(tǒng)制造商用于提高曲面加工效率和質(zhì)量的熱點(diǎn)技術(shù)。本文提出了一種G~2連續(xù)B樣條全局光順?biāo)惴安逖a(bǔ)技術(shù),以及一種基于轉(zhuǎn)角誤差分配的連續(xù)微小線段轉(zhuǎn)角局部光順和轉(zhuǎn)角速度優(yōu)化方法,實(shí)現(xiàn)了基于前瞻窗口的連續(xù)微小線段實(shí)時(shí)光順、轉(zhuǎn)角速度優(yōu)化和綜合約束下跨段自適應(yīng)速度規(guī)劃,將上述方法集成于開放式數(shù)控系統(tǒng)中,實(shí)現(xiàn)了微小線段軌跡的高速加工,驗(yàn)證了本文所提出方法的有效性和實(shí)用性。主要研究內(nèi)容和創(chuàng)新性成果如下:(1)提出了微小線段路徑G~2連續(xù)全局光順和線性/樣條混合路徑跨段加減速方法。運(yùn)用三次B樣條插值擬合算法實(shí)現(xiàn)了微小線段路徑的數(shù)據(jù)壓縮和G~2連續(xù)全局光順;提出了基于減速特征方程的S曲線加減速策略,在滿足機(jī)床加減速特性和刀路軌跡幾何特性對(duì)進(jìn)給速度及加速度約束下,對(duì)生成的線性/樣條混合路徑進(jìn)行了跨段前瞻速度規(guī)劃。該方法適用于短而數(shù)量多的密集線段路徑和轉(zhuǎn)角很小的平緩路徑,可大幅提高進(jìn)給速度平穩(wěn)性和加工效率。勺模加工實(shí)驗(yàn)中,與不采用該方法相比,該方法提高加工效率約4倍。(2)建立了三軸線性刀具路徑轉(zhuǎn)角誤差分配模型和轉(zhuǎn)角速度優(yōu)化方法。以獲取最優(yōu)轉(zhuǎn)角過渡速度為目標(biāo),將系統(tǒng)設(shè)定精度分配為光順近似誤差和插補(bǔ)弓高誤差,在誤差約束下,用Bézier過渡曲線對(duì)(BTP)實(shí)現(xiàn)了線性路徑轉(zhuǎn)角的光順,同時(shí)考慮機(jī)床各軸伺服能力約束,運(yùn)用前瞻功能實(shí)現(xiàn)了微小線段刀路的實(shí)時(shí)插補(bǔ)。面具加工實(shí)驗(yàn)中,與不采用轉(zhuǎn)角誤差分配模型方法相比,在保證軌跡精度前提下,該方法可以將加工時(shí)間縮短25%。(3)建立了五軸工件坐標(biāo)系下的線性刀具路徑的轉(zhuǎn)角誤差分配模型和工作坐標(biāo)下的線性刀具路徑的G~2連續(xù)實(shí)時(shí)擬合方法。將系統(tǒng)設(shè)定精度分配為刀尖點(diǎn)和刀軸點(diǎn)的光順近似誤差和插補(bǔ)弓高誤差,在線段連接處插入兩條三次Bézier曲線,將工作坐標(biāo)下的線性刀具路徑實(shí)時(shí)擬合為G~2連續(xù)的雙樣條軌跡。該算法滿足了近似誤差約束、參數(shù)化同步約束和曲率連續(xù)約束等條件,進(jìn)一步綜合考慮曲線過渡誤差與插補(bǔ)誤差、最大切向加速度/加加速度、機(jī)床各軸伺服能力等約束條件,進(jìn)行了自適應(yīng)速度規(guī)劃,實(shí)現(xiàn)了五軸微小線段的高速加工。通過仿真和實(shí)驗(yàn),該算法在五軸線性刀具路徑光順、轉(zhuǎn)角速度平滑、轉(zhuǎn)角軌跡精度控制方面具有良好的效果。(4)研究了通過給伺服電機(jī)施加正反方向激勵(lì)獲取機(jī)床各軸速度-加速度包絡(luò)圖的實(shí)驗(yàn)方法。通過對(duì)包絡(luò)圖中速度和加速度可行范圍分析,采用最大值匹配法和自適應(yīng)匹配法,得到了優(yōu)化的最大速度和最大加速度約束值,并將約束值應(yīng)用于數(shù)控系統(tǒng)插補(bǔ)運(yùn)算。(5)開發(fā)了基于多線程并發(fā)執(zhí)行管理調(diào)度機(jī)制的開放式數(shù)控系統(tǒng),并對(duì)本文高速微小線段插補(bǔ)算法進(jìn)行了集成應(yīng)用。將三次B樣條全局光順?biāo)惴ê突谵D(zhuǎn)角誤差分配模型Bézier轉(zhuǎn)角過渡算法集成應(yīng)用在廣州數(shù)控GSK27全數(shù)字總線式高檔數(shù)控系統(tǒng)中,實(shí)現(xiàn)了模具的高速加工。將基于五軸轉(zhuǎn)角誤差模型工件坐標(biāo)系局部光順?biāo)惴ê捅孀R(shí)的參數(shù)集成應(yīng)用于廣州數(shù)控GSK25i五軸聯(lián)動(dòng)加工數(shù)控系統(tǒng)中,應(yīng)用于模具高速銑削和復(fù)雜空間曲線零件加工。
[Abstract]:High-speed machining technology is widely used in the manufacturing of aerospace, automobile, and mould. It is an important means to improve the processing quality and efficiency, and the International Institute of Production Engineering (CIRP) has identified the high-speed machining technology as one of the center of the manufacturing technology in the 21st century. The small line segment is the most widely used form of the machining path of complex curved surface parts such as the impeller, the blade, the die and the like, and the high-speed machining of the micro-segment path has become one of the core technologies of the high-speed machining of the complex curved parts. The discontinuous characteristic of the corner in the path of the micro-segment can lead to frequent acceleration and deceleration, which becomes the bottleneck of the high-speed and smooth movement of the numerical control machine. Continuous micro-segment rotation angular velocity smoothing and cross-section speed planning are the most difficult problem for continuous micro-line segment interpolation, and is still a hot spot technology for advanced numerical control system manufacturers to improve surface processing efficiency and quality. The invention provides a G-2 continuous B-spline global fairing algorithm and a interpolation technique, The method is integrated in the open-end numerical control system to realize the high-speed processing of the trace of the micro-segment, and the validity and practicability of the proposed method are verified. The main research contents and innovative results are as follows: (1) The method of continuous global fairing and linear/ spline hybrid path cross-section plus speed reduction is proposed. The data compression and G ~ 2 continuous global fairing of the path of the micro line segment are realized by using the cubic B-spline interpolation fitting algorithm, and the S-curve plus speed reduction strategy based on the deceleration characteristic equation is proposed, and the acceleration and deceleration characteristics of the machine tool and the geometric characteristics of the path of the tool path are met, A cross-segment forward speed planning is carried out on the generated linear/ spline mixing path. The method is suitable for a short and large number of dense line segment paths and smooth paths with small corners, and can greatly improve the feeding speed stability and the processing efficiency. In the ladle mold processing experiment, the method can improve the processing efficiency by about 4 times compared with the method without using the method. and (2) a three-axis tool path angle error distribution model and an angular velocity optimization method are established. in ord to obtain that transition speed of the optimal rotation angle as the target, the system setting precision is assign as the smooth approximation error and the interpolation arch high error, under the error constraint, the light of the linear path angle is realized by the B-Bezier transition curve pair (BTP), and the servo capability constraint of each axis of the machine tool is taken into account, and the real-time interpolation of the micro-segment knife path is realized by using the forward-looking function. in the mask processing experiment, the processing time can be shortened by 25%, compared with the method that does not adopt the corner error distribution model method, and the processing time can be shortened by 25% under the premise of ensuring the track precision. and (3) establishing a G-2 continuous real-time fitting method of a linear tool path under a five-axis workpiece coordinate system and a linear tool path under the working coordinate. The system setting accuracy is assigned as the light-to-close approximation error of the nose point and the knife-axis point and the high-error of the interpolation bow. Two cubic B-spline curves are inserted at the joint of the line segment, and the linear tool path under the working coordinate is fitted into the G-2 continuous double-spline track in real time. The method satisfies the conditions of approximate error constraint, parametric synchronization constraint and curvature continuous constraint, and further comprehensively considers the constraint conditions of the curve transition error and the interpolation error, the maximum tangential acceleration/ acceleration, the servo capability of each axis of the machine tool, and the like, and carries out the self-adaptive speed planning, and the high-speed machining of the five-axis micro-segment is realized. Through the simulation and experiment, the algorithm has good effect in the five-axis tool path fairing, the smooth rotation speed and the angle track precision control. (4) The experimental method of obtaining the velocity-acceleration envelope of each shaft of the machine tool by applying the positive and negative direction excitation to the servo motor is studied. By analyzing the feasible range of velocity and acceleration in the envelope graph, the maximum speed and the maximum acceleration constraint value are obtained by using the maximum matching method and the adaptive matching method, and the constraint value is applied to the interpolation operation of the numerical control system. (5) The open-end numerical control system based on multi-thread concurrent execution management and scheduling mechanism is developed, and the high-speed micro-segment interpolation algorithm is applied in this paper. The three-time B-spline global light-smoothing algorithm and the angle-based error distribution model B-Bezier-angle transition algorithm are integrated and applied in the full-digital bus-type high-end numerical control system of the Guangzhou numerical control GSK27, and the high-speed machining of the die is realized. The local fairing algorithm and the identification parameter integration of the workpiece coordinate system based on the five-axis corner error model are applied to the CNC GSK25i five-axis linkage processing numerical control system, and is applied to the machining of high-speed and complex space curve parts of the die.
【學(xué)位授予單位】：上海交通大學(xué)
【學(xué)位級(jí)別】：博士
【學(xué)位授予年份】：2015
【分類號(hào)】：TG659

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