飞轮储能系统转子动力学分析

文中对储能飞轮转子支撑系统的转子动力学问题进行了研究,推导出各部件的动能、势能和耗散函数,基于拉格朗日方法建立飞轮转子支撑系统的动力学数学模型,并进行求解。采用ANSYS软件对其进行临界转速及不平衡响应求解,并分析磁轴承刚度和阻尼对飞轮转子动态特性的影响。结果表明:系统临界转速均在工作转速范围之内,磁轴承刚度和阻尼的增加有利于系统的稳定,且系统在启动过程中受到不平衡激励时状态趋于稳定。     

静压轴承对电主轴转子系统动态特性的影响分析

静压轴承的性能对高精密平面磨床电主轴转子系统的动态特性起决定性的影响。以某高精密平面磨床电主轴转子系统为研究对象,应用弹簧阻尼单元模拟静压轴承,建立电主轴转子系统的有限元模型,分析其动态特性,得到静压轴承刚度及阻尼值对电主轴转子系统固有频率、动刚度及临界转速的影响特点。结果表明:前后端静压轴承刚度相同时,电主轴转子系统固有频率、临界转速与轴承刚度、阻尼成正变关系,动刚度与轴承刚度成反变关系与轴承阻尼成正变关系,轴承刚度大于3×105N/mm时,轴承阻尼值对系统临界转速影响很小,此时提高轴承阻尼值可以提高系统固有频率和动刚度,减小振动幅度,获得良好的动态性能;前后端静压轴承刚度不相同时,轴承刚度的波动对系统最小动刚度的影响比轴承刚度相同时更柔和,加工更稳定。     

基于内置力执行器的铣削颤振的主动控制

高速加工中铣削颤振不仅降低工件的表面加工质量,严重时还会造成刀具或者其他加工部件的损坏,因此对电主轴铣削颤振进行控制具有重要的意义。为对电主轴铣削过程中的颤振进行有效控制,在双绕组无轴承感应电动机的基础上,提出一种具有内置力执行器的感应型高速电主轴结构,建立电主轴—刀具系统的有限元模型、动态铣削模型、双绕组感应型电主轴电磁力模型,在对具有内置力执行器的感应型高速电主轴电磁力进行解耦后,提出基于内置力执行器的电主轴铣削颤振的主动控制方案,通过仿真分析控制器的主要参数对电主轴铣削稳定性的影响。结果表明采用具有内置力执行器的感应型高速电主轴能够有效地提高电主轴铣削的稳定区域以及在抑制铣削颤振方面具有明显效果。     

磁气负载比对箔片-磁力混合轴承支承特性及转子动力学特性的影响

箔片-磁力混合轴承是一种能降低箔片轴承起飞前的摩擦损耗且可改善磁轴承高速时的承载和动力学性能的新型高性能主动控制型轴承。提出了一种箔片-磁力混合轴承的设计方法,设计并搭建箔片-磁力混合轴承支承特性实验台和箔片-磁力混合轴承转子实验台,实验探究了磁气负载比(即气体箔片轴承和主动磁轴承之间的载荷分配比)对箔片-磁力混合轴承支承特性和转子动力学特性的影响。实验结果表明：箔片-磁力混合轴承比箔片轴承的总体静态刚度和刚度变化率有所提高。箔片-磁力混合轴承结构刚度随频率的提高而增大,等效黏性阻尼随频率的提高呈现先降后增的趋势。此外,合适的负载比可以降低起飞转速,改善摩擦损耗,抑制次频振,有利于提高转子的高速稳定性。     

磁悬浮电动机柔性转子振动控制与试验研究

针对磁悬浮电动机柔性转子穿越一阶弯曲临界转速所面临的问题,提出综合多种控制器于一体的振动控制方法。为保证控制器设计的准确度,采用在线扫频技术验证磁轴承系统各环节建模的正确性。基于不完全微分PID控制器,设计固定中心频率的陷波器抑制转子二阶弯曲模态。根据等效控制系统的阻尼特性,设计相位补偿器增加转子在一阶弯曲模态共振点附近的正阻尼,抑制转子一阶弯曲模态。考虑到转子存在较大的二阶柔性不平衡质量,根据最小电流控制准则,在转子穿越一阶弯曲临界转速之后启用同频陷波器,消除功放同频电流,避免磁轴承控制量过大造成功放电压饱和。试验结果表明,所设计的综合控制器有效抑制了转子的一阶和二阶弯曲模态,且转子在一阶弯曲模态处的最大位移振幅仅为轴承单边保护间隙的5%;最终转子成功穿越一阶弯曲临界转速,并稳定运行在转速34 000 r/min。     

主动磁轴承电主轴的磨削试验

通过现场磨削试验检验主动磁轴承电主轴的磨削性能。磁轴承控制器是以浮点DSP芯片TMS320C32为核心构建的数字控制系统。针对轴承套圈内圆磨削时主轴转子受力的特点确定了合适的控制器参数,使电主轴静态稳定悬浮并以60kr/min工作转速稳定运转,同频振幅小于8μm,轴承刚度达到22~58MN/m。现场磨削试验表明该磁悬浮电主轴的磨削精度已基本达到要求,精磨磨削效率接近工业应用水平。     

新型同位阻尼磁轴承模型及其特性研究

针对以往磁轴承转子系统的振动抑制能力不足的问题,对新型同位电磁阻尼和单自由度磁轴承转子系统进行了研究,提出了一种同位电磁阻尼并应用到抑制磁悬浮转子的振动中。基于以往阻尼力模型重新推导了同位阻尼力数学模型,考虑了线圈电流变化对阻尼力模型的影响,并利用磁矢位计算使阻尼力模型更加精准,分析了同位阻尼力在转子上的分布情况及与电流和位移的关系。将同位阻尼与单自由度磁轴承相结合,建立了新型同位阻尼磁轴承模型,利用该磁轴承模型对同位阻尼抑制转子振动能力进行了分析。仿真结果表明,新型磁轴承模型中的同位阻尼能够将转子最大振动位移偏差从无阻尼时的1.65×10-5m减小到2×10-6m,明显地减小了转子系统的位移偏差,能够达到增强磁轴承转子系统抑制振动能力的目的。     

挠性转子变刚度阻尼支承系统振动主动控制（二）：次优控制规律

从理论上研究了采用变刚度阻尼支承主动控制转子——轴承系统的振动问题,分析和提出了在振动最优主动控制规律的有效频率范围以外,对转子——轴承系统进行次优振动主动控制的策略思想,及变刚度阻尼支承振动次优主动控制规律。根据此规律,从理论上阐明了采用变刚度阻尼支承,对转子——轴承系统进行过临界转速时的振动主动控制的原理和依据。作为示例,就一个三圆盘双支承的转子系统进行计算机仿真。仿真结果说明了本文分析的正确性及其对采用变刚度阻尼支承系统实现挠性转子振动主动控制的的理论指导意义。     

基于ANSYS Workbench的飞轮转子临界转速计算分析

以电磁轴承支撑的飞轮转子为研究对象,建立飞轮转子的有限元模型,基于ANSYS Workbench软件对转子系统临界转速进行求解。分析了阻尼和支撑刚度对飞轮转子系统前三阶临界转速的影响。结果表明,阻尼对飞轮转子临界转速没有影响,支撑刚度使临界转速增加,并计算出最佳的支撑刚度调整范围。     

电磁阻尼器分段相位控制研究

对柔性转子轴承系统，用电磁阻尼器实施主动控制时采用分段位控制算法，按转速频率分段设置不同的优化相位超前补偿环节，以便在整个转速范围内有效控制转子过临界振动，获得较好的控制效果，分段相位控制器能提供随转速而变的刚度阻尼特性，实现变刚度及变刚度阻尼控制过程，实验证明，控制算法简单，抑制效果和稳定性好，具有效大实用价值。     

STUDY ON ELECTRORHEOLOGICAL FLUID DAMPER FOR APPLICATION IN MACHINING CHATTER CONTROL

The electrorheological fluid(ERF)is a kind of intelligent material with bright prospects for industry applications, which has viscoelastic characteristic: under the applied electric field. The dynamic model of a milling system with an ERF damper is established, and the chatter suppression mechanism of the ER effect is discussed theoretically. Both the theoretical study and the experimental investigation show that the additional damping and additioaal stiffness produced by the ERF increase with the rise in the strength of electric field E, but their influence on the cutting stability is different. Only when both additional damping and additional stiffress cooperate, the milling chatter can be suppressed quickly and effectively. In additional, an ERF dumper used on the arbor of horizontal spindle milling machine is developed, and a series of milling shatter control experiments are performed. The experimental results show that the milling chatter can be suppressed effectively by using the ER damper.     

Chatter vibration surveillance by the optimal-linear spindle speed control

The paper concerns self-excited chatter vibration during high speed slender ball-end milling. Non-stationary cutting process, with inclusion of various approaches towards dynamic characteristics of the process, is described. Dynamic analysis of the milling process is performed and dynamics of controlled closed loop system with time-delay is presented. In order to reduce vibration level, instantaneous change in the spindle speed appears as a control command, and thus—the method of vibration surveillance by the spindle speed optimal-linear control is developed. Presented cutting models have been applied for the proposed method and procedure of the chatter vibration surveillance with a use of variable spindle speed has been developed. Computer simulations are performed for selected cases of ball-end milling at constant and variable spindle speed. The results of them are successfully confirmed by experimental investigations on the Alcera Gambin 120CR milling machine equipped with the S2M high speed electrospindle.     

Modeling and performance evaluation of machining spindle with active magnetic bearings

Active magnetic bearings (AMBs) are increasingly employed in the machine tool industry to exploit their advantages over classical bearings such as high speed capability, rotation accuracy, high stiffness, and accurate displacement tracking capability. Furthermore, the possibility of on-line monitoring of the machining process (e.g., cutting force measurement, tool wear) makes AMB spindles very appealing to the High-Speed Machining (HSM) industry. Despite significant progress already reached in HSM technology, there remain numerous open challenges in modeling and control of magnetic bearings as applied to machining spindles. These include optimum control given AMB magnetic saturation levels, management of nonlinear effects, reduction of chatter, and rotor properties. This paper describes a five-degree-of-freedom, high-speed machining spindle supported on AMBs. The rotordynamic modeling and experimentally extracted transfer functions are presented and analyzed. The experimentally measured tool tip compliance is used to compare PID and mu-synthesis control schemes. The primary finding is that the achieved tool tip stiffness is substantially higher with the μ-synthesized controllers than with the best PID we were able to design.     

Chatter prediction based on frequency domain solution in CNC pocket milling

Chatter has been a problem in CNC machining process especially during pocket milling process using an end mill with low stiffness. Since an iterative time-domain chatter solution consumes a computing time along tool paths, a fast chatter prediction algorithm for pocket milling process is required by machine shop-floor for detecting chatter prior to real machining process. This paper proposes the systematic solution based on integration of a stability law in frequency domain with geometric information of material removal for a given set of tool paths. The change of immersion angle and spindle speed determines the variation of the stable cutting depth along cornering cut path. This proposed solution transforms the milling stability theory toward the practical methodology for the stability prediction over the NC pocket milling.     

基于开放式控制器的铣削颤振在线抑制

为实现在线抑制铣削颤振,对颤振领域常用的传感器监控技术,尤其是三向切削力和振动加速度传感器的各向分量在颤振监控过程中的时域和频域敏感信号特征进行试验研究。针对监控的颤振敏感信号频域特性,研究快速傅里叶变换技术对信号有效信息的在线提取技术。对自激颤振的机理进行分析,建立颤振频率与主轴转速间的关系模型,为实现变主轴转速抑制自激颤振提供理论基础。对集成在线参数采集、反馈控制的全软件型模块化铣削控制器进行设计,将在线抑制颤振的相关变主轴转速算法嵌入开放式控制器中,并设计控制参数数据流在控制器模块间的实现流程。对连续变切削深度铝合金工件进行在线颤振抑制加工试验,试验验证开放式智能铣削控制器在线抑制颤振相关技术的正确性。     

圆角铣削颤振稳定域建模与仿真研究

为避免在圆角铣削加工中产生颤振,建立考虑再生作用的圆角铣削动力学模型,推导其平均方向力系数计算公式。鉴于圆角铣削时主轴转速通常远大于圆角处的进给角速度,两者的平均方向力系数近似相等。因此,经典直线铣削颤振稳定域解析模型适用于圆角铣削,前提是需要用最大径向啮合角代替名义径向啮合角进行仿真。根据铣刀与工件的啮合情况,将圆角铣削分为均匀切宽圆角铣削和非均匀圆角切宽铣削两类,并分别推导出其最大径向啮合角计算公式。在动力学建模基础上开发圆角铣削颤振稳定域仿真模块,仿真结果得到了切削试验的验证,为圆角铣削切削参数的选择提供了一条有效途径。     

Chatter prediction utilizing stability lobes with process damping in finish milling of titanium alloy thin-walled workpiece

Machining chatter often becomes a big hindrance to high productivity and surface quality in actual milling process, especially for the thin-walled workpiece made of titanium alloy due to poor structural stiffness. Aiming at this issue, the stability lobes are usually employed to predict if chatter may occur in advance. For obtaining the stability lobes in milling to avoid chatter, this article introduces an extended dynamic model of milling system considering regeneration, helix angle, and process damping into the high-order time domain algorithm which can guarantee both high computational efficiency and accuracy. Via stability lobes, the reasonability and accuracy of the proposed method are verified globally utilizing specific examples in literature. More convincingly, the time-domain numerical simulation is also implemented to predict vibration displacement for partial stability verification. In this extended model, process damping is well-known as an effective approach to improve the stability at low spindle speeds, and particularly, titanium alloy as typical difficult-to-machine material is generally machined at low spindle speeds as well due to its poor machinability. Therefore, the proposed method can be employed to obtain the 3D stability lobes in finish milling of the thin-walled workpiece made of titanium alloy, Ti-6Al-4V. Verification experiments are also conducted and the results show a close agreement between the stability lobes and experiments.     

SUPPRESSION OF PERIOD DOUBLING CHATTER IN HIGH-SPEED MILLING BY SPINDLE SPEED VARIATION

Spindle speed variation is a well known technique to suppress regenerative machine tool vibrations, but it is usually considered to be effective only for low spindle speeds. In the current paper, spindle speed variation is applied to the high speed milling process, at the spindle speeds where the constant speed cutting results in period doubling chatter. The stability analysis of triangular and sinusoidal shape variations is made numerically with the semi-discretization method. It is shown that the milling process can be stabilized by increasing the amplitude of the spindle speed variation, while the frequency of the variation has no significant effect on the dynamic behaviour. The results are validated by experiments. Based on the analysis of the machined workpieces, it is shown that the surface roughness can also be decreased by the spindle speed variation technique.     

Chatter stability prediction in milling using time-varying uncertainties

The chatter stability in milling severely affects productivity and quality of machining. Tool wear causes both the cutting coefficient and the process damping coefficient, but also other parameters to change with cutting time. This variation greatly reduces the accuracy of chatter prediction using conventional methods. To solve this problem, we consider the cutting coefficients of the milling system to be both random and time-varying variables and we use the gamma process to predict cutting coefficients for different cutting times. In this paper, a time-varying reliability analysis is introduced to predict chatter stability and chatter reliability in milling. The relationship between stability and reliability is investigated for given depths and spindle speeds in the milling process. We also study the time-varying chatter stability and time-varying chatter reliability methods theoretically and with experiments. The results of this study show that the proposed method can be used to predict chatter with high accuracy for different cutting times.