车削过程的三维数值分析

利用三维有限元方法,按照实际加工条件建立了切削模拟模型,得到了温度分布、切削力变化和应力场分布等结果。结果表明相对于二维模拟,三维模拟更加真实地揭示了刀具和工件的切削状态,同时也为研究金属切削理论和开发新的刀具提供了一个更加有效的方法。     

高速切削温度场的三维有限元建模与动态仿真

根据温度场控制方程及其边界条件,建立高速切削的三维有限元分析模型,将切削过程的温度分布和变化情况以及切削速度、进给量和切屑厚度等对切削温度的影响进行仿真分析,与相同切削条件下的二维仿真结果和实际测试结果进行对比,可以得出结论:三维建模仿真得到的高速切削温度变化趋势与相关文献结果基本一致,但三维仿真获得的温度值比二维仿真要高些,并且三维仿真的温度值更接近于实际测量值。     

基于三维CAD的三维CAPP系统

针对二维CAPP(Computer Aided Process Planning)中存在的工艺数据更新困难和工序模型无法利用设计模型直接生成的问题,建立了一种基于三维CAD(Computer Aided Design)的CAPP系统。在三维CAD平台上利用参数化特征造型技术,以工艺模型为核心,无需中间环节,实现了三维CAD和三维CAPP系统之间的数据传递,进而解决了工艺数据更新和工序模型生成等问题。该系统目前已被国内某航空企业采用,提高了其工艺编制效率。     

超精密加工的三维表面形貌预测

描述并建立了仿真超精密加工的三维表面形貌模型。三维表面形貌模型由切削参数,刀具几何形状及刀具与工件的相对运动来表征,通过将预测的表面粗糙度轮廓线性映射到网格 面元上来生成已加工表面的形貌,实际的加工和测量实验表明,仿真的三维表面形貌和由激光干涉形貌仪测量得到的三维形貌具有很好的相似性。该模型可用来确定如刀具切削运动的迹线,表面波度等表面特征。     

基于动力学不确定性的重型切削工艺参数优化

针对数控重型切削加工过程的切削稳定性具有不确定性的特点,提出了在切削稳定性和机床工作能力的约束下,获得最大材料去除率的工艺参数优化方法。根据重型切削加工的工艺特点建立三维动力学模型,以机床的固有频率、阻尼比、刚度和切削力系数作为不确定因素,结合排零定理和边理论对其进行不确定性分析,获得稳健的切削稳定性叶瓣图,结合切削深度、刀具直径和刀具齿数的关系,为加工过程选择能获得最大切削深度的刀具。在此基础上,建立工艺参数优化模型,选择最佳的轴向切削深度、径向切削深度和主轴转速的组合,最后以一台加工中心上某型号发动机缸体表面的粗加工过程为例进行了验证。     

汽轮机转子三维工艺的探索研究

针对转子二维工艺加工效率低和数控机床利用率低的缺点,对三维工艺进行了探索研究。以典型转子的加工过程为模板,建立了实际加工的机床、刀具模型和转子成品、毛坯模型,利用EdgeCAM和Vericut软件进行了数控编程、虚拟加工、程序验真及修正,最后制作了三维工艺说明书和加工视频,将原纸质工艺与三维工艺进行了对比。结果表明,转子三维工艺清晰直观地展现了转子的整个加工过程,能够指导新员工独立完成加工任务,减少其学习时间,提高转子的生产效率,降低生产成本。     

三维超声辅助磨削的表面质量研究

针对三维超声辅助磨削加工方法的研究,建立砂轮磨粒切削运动模型,推导单颗磨粒切削轨迹方程,通过仿真分析二维和三维超声辅助磨削单颗磨粒切削轨迹,初步得出三维超声辅助磨削有望得到更优的表面质量。通过三维超声辅助磨削加工试验并观测陶瓷试件的表面粗糙度和微观形貌,证明三维超声辅助磨削的陶瓷表面粗糙度值相对较小,表面轮廓相对平整,三维超声辅助磨削能得到比二维超声辅助磨削更优的表面质量。     

切削颤振分析与模糊控制实验研究

切削颤振是影响金属切削加工生产率和加工质量的重要因素。建立了金属切削过程的二维颤振数学模型;对颤振的稳定性进行了线性分析和非线性分析;并以颤振位移作为反馈变量,建立了基于二维模糊控制器的颤振控制系统。实验结果表明,该分析与控制对降低加工表面粗糙度具有重要意义。     

汽车三维虚拟道路重构系统的设计与实现

为实现汽车标准等级路面谱和实测路面谱的重构,建立空间坐标系下路面不平度的一维Autoregressive(AR)模型和二维双自变量AR模型.通过对自相关系数矩阵进行奇异值分解,将双自变量路面不平度AR模型转换为两个单自变量AR模型,降低了建模的复杂程度.利用建立的二维AR模型对B级标准路面和实测路面进行重构,通过功率谱对比,验证了模型的正确性.基于上述一维和二维路面不平度AR模型以及Visual C++与Matlab混合编程方法,构建汽车三维虚拟道路重构软件系统,给出系统的框架结构.系统通过将路面不平度数据添加在路形上,可生成由规则化路面节点的三维坐标信息所构成的三维虚拟道路.通过对VPG、CarSim和ADAMS三种应用软件路面文件的格式进行分析,给出系统利用三维虚拟道路信息生成上述三种应用软件路面文件的方法.     

汽车模具棱边的三维自适应测量及六维加工轨迹划分

针对大型汽车冲压模具棱边数字化的问题提出了三维自适应测量算法。为满足激光表面强化加工的特殊要求，在后续测量数据处理过程中建立了复杂棱边的简单模型，提出了六维加工轨迹划分算法，并对算法进行了加工实验验证。所提出的算法已应用到集成化柔性激光加工系统中。     

铣削加工系统三维稳定性理论研究与进展

切削颤振是高速加工过程中经常遇到的一种现象,而判断稳定切削常用的一种方法就是绘制稳定性图。主要针对国内外铣削加工颤振三维稳定性图和三维稳定性理论研究状况进行了综述,重点给出了Thevenot、U.Bravo和S.Herranz、Tony L.Schmitz和Altintas的稳定性理论。研究指出,为了保证材料的最大去除率,必须研究切削参数对于稳定性的影响,也就是需要研究主轴转速、轴向切深和径向切深对切削颤振影响的三维稳定性图。     

Observation of three-dimensional internal structure of steel materials by means of serial sectioning with ultrasonic elliptical vibration cutting

A three-dimensional (3D) internal structure observation system based on serial sectioning was developed from an ultrasonic elliptical vibration cutting device and an optical microscope combined with a high-precision positioning device. For bearing steel samples, the cutting device created mirrored surfaces suitable for optical metallography, even for long-cutting distances during serial sectioning of these ferrous materials. Serial sectioning progressed automatically by means of numerical control. The system was used to observe inclusions in steel materials on a scale of several tens of micrometers. Three specimens containing inclusions were prepared from bearing steels. These inclusions could be detected as two-dimensional (2D) sectional images with resolution better than 1 μm. A three-dimensional (3D) model of each inclusion was reconstructed from the 2D serial images. The microscopic 3D models had sharp edges and complicated surfaces.     

Three-dimensional process stability prediction of thin-walled workpiece in milling operation

High-speed machining of thin-walled workpiece is widely used in aerospace industry. To optimize the machining parameters in milling operations, the related process stability is required to be predicted. Compared to the existing two-dimensional (2D) milling stability model, a more completed three-dimensional (3D) regenerative process stability prediction model of thin-walled workpiece is presented based on the newly developed dynamic model. The efficiency and accuracy of the regenerative milling stability can be improved in the presented 3D model. The analysis procedure of the stability of flexible dynamic milling is developed in details. The 3D stability lobes are calculated according to the full discretization method and direct integration scheme. To verify the accuracy of presented 3D stability model, the thin-walled workpiece milling sound pressure signal and surface quality are determined in experiments.     

Improved dynamic cutting force model in ball-end milling. Part I: theoretical modelling and experimental calibration

An accurate cutting force model of ball-end milling is essential for precision prediction and compensation of tool deflection that dominantly determines the dimensional accuracy of the machined surface. This paper presents an improved theoretical dynamic cutting force model for ball-end milling. The three-dimensional instantaneous cutting forces acting on a single flute of a helical ball-end mill are integrated from the differential cutting force components on sliced elements of the flute along the cutter-axis direction. The size effect of undeformed chip thickness and the influence of the effective rake angle are considered in the formulation of the differential cutting forces based on the theory of oblique cutting. A set of half immersion slot milling tests is performed with a one-tooth solid carbide helical ball-end mill for the calibration of the cutting force coefficients. The recorded dynamic cutting forces are averaged to fit the theoretical model and yield the cutting force coefficients. The measured and simulated dynamic cutting forces are compared using the experimental calibrated cutting force coefficients, and there is a reasonable agreement. A further experimental verification of the dynamic cutting force model will be presented in a follow-up paper.     

A novel chatter stability criterion for the modelling and simulation of the dynamic milling process in the time domain

The modelling of the dynamic processes in milling and the determination of chatter-free cutting conditions are becoming increasingly important in order to facilitate the effective planning of machining operations. In this study, a new chatter stability criterion is proposed, which can be used for a time domain milling process simulation and a model-based milling process control. A predictive time domain model is presented for the simulation and analysis of the dynamic cutting process and chatter in milling. The instantaneous undeformed chip thickness is modelled to include the dynamic modulations caused by the tool vibrations so that the dynamic regeneration effect is taken into account. The cutting force is determined by using a predictive machining theory. A numerical method is employed to solve the differential equations governing the dynamics of the milling system. The work proposes that the ratio of the predicted maximum dynamic cutting force to the predicted maximum static cutting force can be used as a criterion for the chatter stability. Comparisons between the simulation and experimental results are given to verify the new model.     

齿轮误差三维评定方法

研究了齿轮误差三维评定方法,以消除测量仪器定位误差对齿轮误差评定的影响,提高齿轮测量仪器的测量精度。分析了传统齿轮二维评定方法的弊端,提出将齿轮误差评定从二维评定模式转变为三维评定模式。该评定模式不再要求齿轮各项误差测量点位于特征面内,实现了三维空间内的齿轮误差测量与评定。为提高齿轮三维误差评定算法的效率,通过螺旋降维方法将三维数据降至二维数据,再对二维测量数据进行各项误差的评定。以特大型齿轮激光跟踪在位测量系统作为实验对象,对4级标准齿轮的齿廓误差进行了测量,并与传统的齿轮二维误差评定方法以及德国ZEISS公司InvolutePro软件的评定结果进行了对比。结果表明:传统齿轮二维误差评定方法有较大误差,三维齿廓评定方法与德国ZEISS公司InvolutePro软件评定结果一致,精度达到0.1μm,证明了提出的齿廓误差三维评定方法完全正确,可以消除仪器定位误差对测量结果的影响,提高了测量仪器的测量精度。